Chemical Production Processes and Systems

Abstract

Chemical production processes are provided that include reacting a metal comprising olefin to form a conjugated olefin; reacting a heterohalogenated olefin to form a conjugated olefin; reacting a halogenated alkane to form a conjugated olefin; and/or reacting a hydrohalogenated olefin to form a conjugated olefin. Chemical production systems are also provided that can include: a first reactant reservoir configured to house a perhalogenated olefin; a second reactant reservoir configured to house a catalyst mixture; a first reactor coupled to both the first and second reservoirs, the first reactor configured to house a metal-comprising mixture and receive both the perhalogenated olefin form the first reactant reservoir and the reactant mixture from the second reactant reservoir; and a product collection reservoir coupled to the first reactor and configured to house a conjugated olefin.

Description

CLAIM FOR PRIORITY

This application claims priority to U.S. Provisional Patent Application Ser. No. 60/605,232, entitled “Chemical Preparation Processes”, filed Aug. 26, 2004; the entirety of which is incorporated by reference herein.

TECHNICAL FIELD

The present invention relates to the field of chemical production processes and systems and more specifically to the production of conjugated olefins and systems for producing conjugated olefins.

BACKGROUND

Time and efficiency have always played a role in the development of chemical production processes and systems. There is a constant need for the most efficient and reliable processes thereby enabling the least expensive production costs. Recently industries have required high purity specialized compounds for use in manufacturing processes. Hexafluoro-1,3-butadiene (C₄F₆) has been developed for dry etching and semiconductor processing applications. C₄F₆ is just one example of a conjugated olefin that can be prepared according to the processes and systems described herein.

SUMMARY

Chemical production processes are provided that include reacting a metal comprising olefin to form a conjugated olefin; reacting a heterohalogenated olefin to form a conjugated olefin; reacting a halogenated alkane to form a conjugated olefin; and/or reacting a hydrohalogenated olefin to form a conjugated olefin.

Chemical production systems are also provided that can include: a first reactant reservoir configured to house a perhalogenated olefin; a second reactant reservoir configured to house a catalyst mixture; a first reactor coupled to both the first and second reservoirs with the first reactor configured to house a metal-comprising mixture and receive both the perhalogenated olefin from the first reactant reservoir and the reactant mixture from the reservoir; and a product collection reservoir coupled to the first reactor and configured to house a conjugated olefin.

BRIEF DESCRIPTION OF THE DRAWINGS

Embodiments are described with reference to the following accompanying drawings:

FIG. 1 is an exemplary system for preparing compositions according to an embodiment.

FIG. 2 is an exemplary system for preparing compositions according to an embodiment.

FIG. 3 is an exemplary system for preparing compositions according to an embodiment.

DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS

Chemical production processes and systems are described with reference to FIGS. 1-3. Referring first to FIG. 1, a system 10 is disclosed that includes a reaction zone 11 coupled to a heterohalogenated olefin reservoir 12, a metal-comprising mixture reservoir 13 and a reactant mixture reservoir 14. System 10 also includes a product recovery zone 16 and a recycle conduit 15 configured to return by-products separated from products in zone 16 to reaction zone 11. According to exemplary embodiments, reaction zone 11 can include a single reactor or a plurality of reactors. The reactor can be constructed of glass and/or a nickel-alloy such as Inconel® 600 (Special Metals Corporation 3200 Riverside Drive Huntington, W. Va. 25705-1771, USA). These reactors can be configured to control the temperature within the reactor via cooling coils and/or heat tape, for example, depending on the requirements of the temperature within the reactor. The reactor can also be configured to control the pressure within the reactor during the combination of reactants.

According to exemplary embodiments, system 10 can be configured to react a metal-comprising olefin to form a conjugated olefin. The reacting can include exposing the metal-comprising olefin to a reactant mixture to form the conjugated olefin, for example. This exposing can include providing the metal-comprising olefin to within the reactor and providing a reactant mixture to within the reactor. Exemplary embodiments include maintaining the temperature of the contents of the reactor during the providing of the catalyst mixture.

The providing of the metal-comprising olefin can include reacting a heterohalogenated olefin from heterohalogenated olefin reservoir 12 to form the metal-comprising olefin. The heterohalogenated olefin of heterohalogenated olefin reservoir 12 can include a C-2 olefin. The heterohalogenated olefin can also include F and one or more of Cl, Br, and/or I. The heterohalogenated olefin can be C₂F₃Br and/or

for example.

According to exemplary aspects a metal-comprising mixture from metal-comprising mixture reservoir 13 can be provided to reaction zone 11. This mixture can be in the form of a slurry and can include one or more elements from groups 1, 2, 4, 8, 11, 12, and/or 14 of the periodic table of elements and in specific embodiments zinc, as well as, a composition including tetrahydrofuran and/or a polar aprotic solvent such as one or more of acetonitrile, methyl-ethyl-ketone, dimethylformamide, and/or dimethylsulfoxide. The elements may be activated and/or unactivated, for example, unactivated Zn may be utilized. The compositions may be anhydrous and/or contain small amounts of water, such as amounts as high as 0.15% (wt./wt.). For example, a composition of one or more acetonitrile, tetrahydrofuran, methyl-ethyl-ketone, dimethylformamide, and dimethylsulfoxide may be provided to reaction zone 11 followed by providing a metal to zone 11 with the metal and the composition forming the metal-comprising mixture. Within zone 11, the metal-comprising mixture may be heated to a temperature of from about room temperature to about 120° C. According to exemplary embodiments, the temperature of the metal-comprising mixture can be maintained at from about 60° C. to about 70° C., and/or greater than 70° C. The heterohalogenated olefin can be added from heterohalogenated olefin reservoir 12 to form the metal-comprising olefin. In exemplary embodiments, the addition of the heterohalogenated olefin can be performed under atmospheric pressures and in other embodiments, system 10 can be closed and the addition can be performed under a vacuum such as 15 mm Hg.

According to other embodiments the metal-comprising mixture may be heated to about 70° C. and a portion of the molar charge of the heterohalogenated olefin may be added to the mixture. In exemplary embodiments, adding less than molar charge can initiate the production of the metal-comprising olefin. For example, the portion can be at least about 15% to 25% of the molar charge and combined with the metal-comprising mixture within zone 11 to produce the metal-comprising olefin. Upon addition of the portion of the molar charge of the heterohalogenated olefin, production of the metal-comprising olefin can initiate and a remainder of the heterohalogenated olefin may then be added to zone 11 and consumed upon addition. According to exemplary embodiments, adding the portion of the heterohalogenated olefin to initiate the production followed by adding the remainder of the olefin can facilitate temperature and/or pressure control of zone 11 which can also facilitate purification of the conjugated olefin where system 10 is a closed system.

According to other embodiments, a complete charge of the heterohalogenated olefin may be added to the metal-comprising mixture. Upon addition of the complete charge the system can be cooled to control exotherms.

Where system 10 is a closed system, the pressure may be controlled to regulate production and control reaction rates, as well as, efficiency. For example the system may be maintained under vacuum. In other instances the pressure of system 10 may be maintained below about 300 mm Hg and in other instances the pressure can be greater than 20 mm Hg.

The metal-comprising olefin can contain at least one element from groups 1, 2, 4, 8, 11, 12, and/or 14 of the periodic table of elements. The element can be Zn, for example. The metal-comprising olefin also can include one or more of F, Cl, Br, and/or I. The metal-comprising olefin can be heterohalogenated in exemplary embodiments and/or perhalogenated. The metal-comprising olefin can be a C-2 olefin and/or, according to exemplary embodiments, the metal-comprising olefin can include both F and Br. According to other embodiments, the metal-comprising olefin can include F, Br, and/or Zn. In exemplary embodiments, the metal-comprising olefin is

The metal-comprising olefin can be prepared and, in exemplary embodiments, is stable for up to 4 days. As such, according to exemplary embodiments, the reactions can be performed in stages, at separate facilities and/or locations.

The metal-comprising olefin can be reacted to form a conjugated olefin by providing a reactant mixture from reactant mixture reservoir 14 to reactor zone 11. The reactant mixture can include one or more of Fe, Cu, Ni, and/or Mn. The reactant mixture can also include a metal-halide composition and the metal-halide composition can comprise one or more of Fe, Cu, Ni, Mn, F, Cl, Br, and/or I. The reactant mixture can also include one or both of polar aprotic solvents and/or non-polar solvents. Exemplary compositions that can be a component of the reactant mixture can include one or more of acetonitrile, tetrahydrofuran, methyl-ethyl-ketone, dimethylformamide, and dimethylsulfoxide. In exemplary embodiments, the reactant mixture includes FeCl₃. Exemplary reactant mixtures can be stable for use for up to 4 days.

A product mixture including the conjugated olefin can be formed while providing the reactant mixture to zone 11 while maintaining the contents of the reaction zone at less than about 70° C., for example. According to still other embodiments, heating zone 11 to temperatures as high and or greater than 70° C. can facilitate efficient production of the conjugated olefin. For example, the product mixture can include approximately 60% conjugated olefin when zone 11 is maintained below 70° C., however when zone 11 is maintained above 70° C. product mixtures including as high as 90% conjugated olefin can be obtained.

The conjugated olefin formed can include one or more of F, Cl, Br, and/or I. The conjugated olefin can be perhalogenated and/or homohalogenated. The olefin can be perhalogenated with F, for example. In exemplary embodiments, the conjugated olefin is a C-4 olefin. The conjugated olefins can be

for example. The conjugated olefin can be removed from reaction zone 11 and transferred to product recovery zone 16. The conjugated olefin can be removed by increasing the maintained temperature of the contents of the reaction zone 11, for example. In exemplary embodiments, this can include increasing the temperature at least 15% above the maintained temperature; and/or from about 15% to about 30% above the maintained temperature. For example, where the maintained temperature is about 70° C. the conjugated olefin can be removed by increasing the temperature within reaction zone 11 to about 120° C.

As a more specific example, the metal-comprising olefin can include

the reactant mixture can include FeCl₃, and the temperature within the reaction zone upon addition of the reactant mixture to the metal-comprising olefin can be less than about 70° C. The conjugated olefin can include

and the temperature of the reactor can be increased to a temperature greater than about 80° C. to remove the conjugated olefin from the reactor.

According to an exemplary embodiment, within the product recovery zone 16, the conjugated olefin can be purified. This purification can include distilling and drying the conjugated olefin, for example.

The distilling can include providing a product mixture that includes the conjugated olefin and by-products to a distillation apparatus. At least a portion of the mixture can be converted to the gas phase with the portion being converted to the gas phase including at least a portion of the conjugated olefin within the product mixture. A distillate can be recovered comprising the portion of the conjugated olefin with the distillate comprising less by-products than the product mixture.

Either before or after distillation, the conjugated olefin can be dried by exposing a product mixture including the conjugated olefin to one or both of a 3 Å absorbent and/or a 13× molecular sieve, for example. During this exposing to the 3 Å absorbent and/or the 13× molecular sieve, the product mixture can be in a liquid phase, for example.

Further examples of the reactions that can be performed with reference to system 10 are given below with reference to Schemes 1-5.

According to scheme (1) above, in a reaction flask that can be equipped with an agitator, jacketing, a thermocouple, reflux condenser, a product collecting container, a vacuum pump, and a feeding tube which can be slidably coupled to a flask neck member, 600 grams (9.18 moles) of zinc and 3000 grams of N,N-dimethylformamide (DMF) can be added to form a slurry. The slurry can be agitated at from about 0 rpm to 220 rpm and heated to about 70° C. To the slurry, from about 92.4 grams (0.57 mole) to about 231 grams (1.44 moles) of bromotrifluoroethylene can be added subsurface relative to the slurry through the feeding tube to form a mixture. The mixture can be observed to have an exotherm, thereby bringing the mixture temperature to from about 90° to about 120° C. The mixture can then be cooled to about 70° C. whereupon from about 693 grams (4.31 moles) to about 831.6 grams (5.17 moles) of bromotrifluoroethylene can be added through said feeding tube over a period of about 2-664 minutes to form an organometallic mixture. The organometallic mixture can be held, while agitating, at temperature for about one hour. In a separate flask that can be coupled with the reaction flask and equipped with a supplying tube having a needle valve (Teflon), an agitator, and a reflux condenser, 1038 grams (6.4 moles) of ferric chloride (FeCl₃) and 1971 grams of DMF can be added to form an addition mixture. An exotherm can be observed when the DMF and FeCl₃ are combined. The addition mixture can be added dropwise through the feeding tube to the surface of the organometallic mixture to form a reaction mixture. A vacuum of about 10 cm Hg can be applied to the entire reaction system to assist in the delivering of the addition mixture to the organometallic mixture and subsequent removal of the product dimer. The reaction mixture temperature can be held at about 70° C. by using an ice water bath. Near the end of the addition, the reaction mixture can be allowed to warm to from about 80° C. to about 85° C. (feed time range from 9-582 minutes) to facilitate removal of hexafluoro-1,3-butadiene product from reaction mixture into the product collecting container chilled by a dry ice and acetone bath. In the product collecting container, 384 grams (2.37 moles) of hexafluoro-1,3-butadiene product can be collected having a purity by gas chromatography of about 93 percent.

According to scheme (1) above, in a reaction flask that can be equipped with an agitator, jacketing, a thermocouple, reflux condenser, a product collecting container, a vacuum pump, and a feeding tube which can be slidably coupled to a neck of the flask, 100 grams of acetonitrile and 20 grams (0.31 mole) of zinc can be placed to form a mixture. The mixture can be heated to from about 47° C. to about 78° C. and bromotrifluoroethylene can be fed into the reactor over a period of about 95 minutes to form a reaction mixture. During the bromotrifluoroethylene feeding period, the reaction mixture can be observed to change from having a grey color to having a greenish color. The reaction mixture can be heated to about 60° C. and held for from about 15 hours to about 21 hours, and/or about 18 hours whereupon a color change can be observed from greenish to brownish. The flask can be equipped with an addition funnel containing a reactant mixture. The reactant mixture can be prepared by mixing 26.7 grams (0.165 mole) of ferric chloride and 48.1 grams of acetonitrile whereupon an exotherm can be observed. The reactant mixture can be added dropwise to the reaction mixture over a period of about 20 minutes to form a product mixture. The product mixture can contain hexafluoro-1,3-butadiene, which can be collected in the product collecting container. The reactant mixture can be added to the reaction mixture while removing the hexafluoro-1,3-butadiene product from the product mixture, for example. The remainder of product can be driven out of the product mixture by heating to about 80° C. until no more gas evolution can be observed. A total of 4.6 grams of the product can be collected. The product structure as well as reaction efficiency can be confirmed by GC/MS analysis.

In accordance with scheme (1) above, in a reaction flask that can be equipped with an agitator, jacketing, a thermocouple, reflux condenser, a product collecting container, a vacuum pump, and a feeding tube which can be slidably coupled to a neck of the flask, 101 grams of tetrahydrofuran (THF) and 20 grams (0.31 mole) of zinc can be placed to form a mixture. The mixture can be heated to from about 60° C. to about 70° C. and a total of 23.37 grams (0.145 mole) of bromotrifluoroethylene can be fed into the reactor over a period of about 90 minutes to form a reaction mixture. During the bromotrifluoroethylene feeding period, the reaction mixture can be observed to change from having a grey color to having a greenish color. The reaction mixture can be heated to about 60° C. and held for from about 15 hours to about 21 hours, and/or about 18 hours. The flask can be equipped with an addition funnel containing a reactant mixture. The reactant mixture can be prepared by mixing 27.6 grams (0.17 mole) of ferric chloride and 68 grams of tetrahydrofuran (THF). The reactant mixture can be added dropwise to the reaction mixture over a period of about 20 minutes to form a product mixture. The product, hexafluoro-1,3-butadiene, can be collected from the product mixture in the product collecting container. While adding the reactant mixture to the reaction mixture product can be recovered from the product mixture. The remainder of product can be driven out of the product mixture by heating to about 60° C. until no more gas evolution can be observed affording about 6 grams total. The product structure, as well as, reaction efficiency can be confirmed by GC/MS analysis.

Referring to scheme (1) above, in a reaction flask that can be equipped with an agitator, jacketing, a thermocouple, reflux condenser, a product collecting container, a vacuum pump, and a feeding tube which can be slidably coupled to a neck of the flask, 100 grams of methyl-ethyl-ketone (MEK) and 20 grams (0.31 mole) of zinc can be placed to form a mixture. The mixture can be heated to from about 50° C. to about 70° C. and a total of 20.42 grams (0.13 mole) of bromotrifluoroethylene can be fed into the reactor over a period of about 90 minutes to form a reaction mixture. The reaction mixture can be heated to about 60° C. and held for from about 15 hours to about 21 hours, and/or about 18 hours. The flask can be equipped with an addition funnel containing a reactant mixture. The reactant mixture can be prepared by mixing 27.8 grams (0.171 mole) of ferric chloride and 48.4 grams of MEK whereupon an exotherm can be observed. The reactant mixture can be added dropwise to the reaction mixture over a period of about 5 minutes to form a product mixture. The product, hexafluoro-1,3-butadiene, can be collected from the product mixture in the product collecting container. While adding the reactant mixture, the product can collected from the product mixture. A remainder of product can be driven out of the product mixture by heating the mixture to about 80° C. until no more gas evolution can be observed. A total of 2.0 grams of the product can be collected. The product structure, as well as, reaction efficiency can be confirmed by GC/MS analysis.

In reference to scheme (1) above, in a reaction flask that can be equipped with an agitator, jacketing, a thermocouple, reflux condenser, a product collecting container, a vacuum pump, and a feeding tube which can be slidably coupled to a neck of the flask, 107 grams of dimethyl sulfoxide (DMSO) and 20 grams (0.31 mole) of zinc can be placed to form a mixture. The mixture can be heated to from about 57° C. to about 85° C. and a total of 20.2 grams (0.125 mole) of bromotrifluoroethylene can be fed into the reactor over a period of about 45 minutes to form a reaction mixture. During the bromotrifluoroethylene feeding period, the reaction mixture can be observed to change from having a grey color to having a greenish color. The reaction mixture can be heated to about 60° C. and held for from about 15 hours to about 21 hours, and/or about 18 hours. The flask can be equipped with an addition funnel containing a reactant mixture. The reactant mixture can be prepared by mixing 28 grams (0.174 mole) of ferric chloride and 52 grams of DMSO. The reactant mixture can be added dropwise to the reaction mixture over a period of about 10 minutes to form a product mixture. The product, hexafluoro-1,3-butadiene, can be collected from the product mixture in the product collecting container. While adding the reactant mixture, the product can be removed from the product mixture. The remainder of product can be driven out of the product mixture by heating the product mixture to about 80° C. until no more gas evolution can be observed. A total of 1.7 grams of the product can be collected. The product structure, as well as, reaction efficiency can be confirmed by GC/MS analysis.

In accordance with scheme (2) above, 2 grams (0.03 mole) of activated zinc and 30 mL of dry dimethylformamide (DMF) can be added to a 3-necked 100 mL round bottom flask fitted with a dry ice condenser to form a slurry. To the slurry, 5.3 grams (0.033 mole) of bromotrifluoroethylene can be added to form an initial mixture. The initial mixture can be warmed slightly to about room temperature, whereupon about 15 minutes later, the reaction can initiate and an exotherm can occur with the temperature rising to about 70° C. To control the exotherm the round bottom flask can be at least partially submerged in ice-water. The initial mixture can be observed to turn brown and can be stirred further for 1 hour at room temperature to form the trifluorovinylzinc bromide. The flask can be fitted with an addition funnel containing a reactant mixture. The initial mixture can be cooled to 0-5° C., a vacuum of approximately 100 mm Hg can be applied, and 0.033 mole of the reactant mixture including, for example ferric salt [FeCl₃ (in some embodiments, added as a solution in dimethylformamide), FeBr₃, Fe(OAc)₃] and/or cupric salt [Copper triflate, CuBr₂, Cu(OAc)₂] can be added slowly to the initial mixture while maintaining the reaction temperature at less than about 5° C. to form a reaction mixture containing the hexafluoro-1,3-butadiene product. Most of the product can be collected in the cold (dry ice-acetone) trap. A remainder of the product can be collected by warming the product mixture to about 40° C. and stirring for 2 hours while maintaining the vacuum. A yield of the reactions can range from about 60-68% as confirmed by GC/MS. Yields can be correlated with the catalysts utilized in accordance with Table 1, below.

TABLE 1
Production Run	Reactant Component	Yield
1	FeCl3	68
2	FeBr3	67
3	Cu(OAc)2	63
4	CuBr2	68
5	Cu(OTf)2	62
	(3)

In accordance with scheme (3) above, under nitrogen, to a 100 mL round bottom flask having a side-arm and fitted with a reflux condenser, 4.2 grams (0.032 mole) of anhydrous zinc chloride, and 30 mL of dry tetrahydrofuran can be added to form an initial mixture. The initial mixture can be cooled to 10° C. and tetrafluoroethane (HFC-134a, 0.036 mole) can be added slowly to form a slurry. Lithium diisopropyl amine (1.8 M solution in heptane/tetrahydrofuran (THF), 0.064 mole) can be added slowly via a syringe to the slurry, while maintaining the temperature at less than about 15° C. to form a reaction mixture. (The tip of the needle of the syringe can be dipped into the slurry to avoid decomposition of trifluorovinyllithium formed by a reaction of HFC-134a with lithium diisopropyl amine). The reaction mixture can be stirred for 1 hour and allowed to warm to room temperature. The reaction mixture can then be cooled to from about 0° C. to about 5° C. while applying vacuum (100 mm Hg). Ferric salt (FeCl₃, FeBr₃, 0.033 mole)] or cupric salt [Copper triflate, Cu(OAc)₂] can be added slowly while maintaining the vacuum and the reaction temperature below about 5° C. to form a final mixture. The final mixture can then be stirred while maintaining the temperature at about 40° C. for two hours and the product can be collected in −78° C. (dry ice-acetone) trap. Yields can be from about 65-70%.

According to scheme (4) above, 18 grams (0.26 mole) of activated zinc and 150 mL of dry dimethylformamide (DMF) can be added to a 250 mL round bottom flask having a side-arm and fitted with a reflux condenser to form a slurry. Zinc dust can be activated by stirring a mixture of 100 grams of zinc powder with 50 mL of 10% dilute hydrochloric acid for 2-4 minutes, filtering and washing the mixture with 100 mL of water followed by 50 mL of acetone and drying the filtrate in an oven at about 130-140° C. for one hour. To the slurry, 42.5 grams (0.26 mole) of bromotrifluoroethylene can be added slowly to the round bottom flask while stirring at room temperature to form a mixture. After 1.5 hours, the reaction can initiate and an exotherm can occur (temperature raises to 50-60° C., for example), which can be controlled by submerging a portion of the reaction flask in an ice water bath. The mixture can turn a brownish color and can be stirred for an additional 3 hours at room temperature. After this stirring, the mixture can be cooled to 0-5° C. and iodine (101 g, 400 mmol) can be added slowly while maintaining the reaction temperature at <15° C. to form a reaction mixture. The reaction mixture can be stirred at room temperature for over night. The product can be distilled at 30-42° C. under nitrogen to obtain 34 grains (62%) of the trifluorovinyl iodide product. Similar reaction chemistries can be used to prepare compounds such as trifluorovinyl chloride and trifluorovinyl bromide as well.

According to scheme (5) above, 8.5 grams (0.132 mole) of activated copper powder and 50 mL of dry dimethylformamide can be added to a 100 mL round bottom flask having a side arm and fitted with a reflux condenser to form a slurry. The activated copper powder can be prepared according to A. I. Vogel, Textbook of Practical Organic Chemistry, 5th Ed. Page No. 426, herein incorporated by reference. According to an exemplary embodiment, 20 grams of copper powder can be exposed to 200 mL of 2% solution of iodine in acetone for 10 minutes to form a grayish colored mixture. The mixture can be filtered and washed with 100 mL of a 1:1 solution of concentrated HCl in acetone. The filtrate of the filtered mixture can be dried under vacuum at 40-50° C.

To the round bottom flask containing the activated copper powder and dimethylformamide, trifluorovinyl iodide 25 grams (0.120 mole) can be added slowly and kept stirring at room temperature to form a reaction mixture. The reaction mixture can be stirred at room temperature for one hour and the product can be collected in a cold trap (−78° C.) with the following results: yield: 6.5 g (67%); conversion 77%; selectivity 74%; mass balance >99%; crude reaction mixture can contain 57% C₄F₆, 23% iodotrifluoroethylene (starting material), and 20% trifluoroethylene (by-product). Qualitative and quantitative analyses can be determined by gas chromatography mass spectrometry utilizing total area counts.

Referring to FIG. 2, a system 20 for reacting a halogenated alkane to form a conjugated olefin is depicted according to an exemplary embodiment. System 20 includes at least two reaction zones, reaction zone 11 as previously described and coupled to reaction zone 21. System 20 also includes a heterohalogenated alkane reservoir 12 which also can be considered a portion of the product recovery zone of reaction zone 21. System 20 also includes a recycling conduit 15 that can be coupled between reactors 11 and 21, as well as, product recovery zone 16. The halogenated alkane within halogenated alkane reservoir 22 can include one or more of F, Cl, Br, and I. The halogenated alkane can be a C-2 alkane and/or the halogenated alkane can be heterohalogenated. The halogenated alkane can have the general formula C₂HF₃Br₂ and in specific embodiments can be

System 20 further includes a reducing-reagent mixture reservoir 23 coupled to reaction zone 21. The reducing-reagent mixture can include a base. The base can be NaOH and/or KOH, for example. According to exemplary embodiments, that base can be KOH and water. Other mixtures can include NaOH and/or KOH and methanol. More particularly, the reducing-reagent mixture can include a 40% (wt./wt.) mixture of KOH and water.

Reaction zone 21 can be configured to expose the halogenated olefin from halogenated olefin reservoir 22 to the reducing-reagent mixture from reducing-reagent mixture reservoir 23. In exemplary embodiments the reducing-reagent mixture can be provided from reservoir 23 to the reaction zone and then the halogenated olefin exposed to the reducing reagent mixture within the reaction zone to form a heterohalogenated olefin. Accordingly, the halogenated alkane can be reacted to form a heterohalogenated olefin and the heterohalogenated olefin can be reacted to form a conjugated olefin, for example, by transferring the heterohalogenated olefin produced in reaction zone 21 to reaction zone 11 and reacting the olefin as described above. The heterohalogenated olefin can be prepared from the halogenated alkane in accordance with scheme 6 below, for example.

In accordance with scheme (6) above, a mixture including 40 (wt/wt) % KOH in water can be provided to a glass-lined reactor equipped with an agitating apparatus. Dibromodifluoroethane can be added to the reactor above the surface of the mixture at about 76° C., ambient pressure, and flow rates of from about 1.3 grams per minute to about 5.1 grams per minute.

Referring to FIG. 3, a system 30 is shown that includes two reaction zones, reaction zone 31 coupled to reaction zone 32. Reaction zone 31 can be configured to be a plurality of reactors and in exemplary embodiments reaction zone 31 can be configured as system 20 previously described or as system 10 previously described. In such configurations, reaction zone 31 can be coupled to a halogenated alkane reservoir 33, which can form a portion of the product recovery reservoir of reaction zone 32. The halogenated alkane can be produced within reaction zone 32 by reacting a hydrohalogenated olefin from a hydrohalogenated olefin reservoir 34 to form the halogenated alkane. The hydrohalogenated olefin within hydrohalogenated olefin reservoir 34 can comprise one or more of F, Cl, Br, and/or I. The hydrohalogenated olefin can be a C-2 olefin such as C₂HF₃ and in exemplary embodiments can be

System 30 also includes a halogenating reagent reservoir 35 coupled to reaction zone 32. The halogenating reagent of the halogenating reagent reservoir can comprise one or more of F, Cl, Br, and/or I. In exemplary embodiments, the halogenating reagent can include Br₂. Utilizing system 30, for example, a hydrohalogenated olefin can be reacted to form a halogenated alkane and the halogenated alkane can be reacted to form a conjugated olefin. As such, the hydrohalogenated olefin can be reacted to form a conjugated olefin.

In exemplary embodiments, the reacting of the hydrohalogenated olefin to form the halogenated alkane can include configuring reaction zone 32 to expose the hydrohalogenated olefin to the halogenating reagent from halogenating reagent reservoir 35. The hydrohalogenated olefin from hydrohalogenated olefin reservoir 34 can be provided to within reaction zone 32 and the hydrohalogenated olefin provided therein can be exposed to the halogenating reagent to form the halogenated alkane. System 30 can also include recycle conduit 15 that can be coupled to reaction zone 31 and 32 as well as halogenated product recovery zone 16. According to exemplary embodiments, the recycled conduits of systems 10, 20, and 30 can be configured to receive at least one by-product from product reservoirs of those systems and convey those by-products to previous points in the systems for conversion of those by-products to the sought after products such as the conjugated olefin. Exemplary aspects of system 30 are described with reference to scheme (7) below.

In accordance with scheme (7) above, to a flask that can be equipped with a magnetic stirrer, reflux condenser, and a gas bubbler, about 10 grams (0.125 mole) of elemental bromine can be placed. The elemental bromine can be exposed to an incandescent lamp, and about 9.24 grams (0.113 mole) of gaseous 1,1,2-trifluoroethene (TFE) can be fed though a rotometer at a rate such that no reflux of TFE can be observed on the condenser, to form a mixture. The mixture can be observed to turn from deep red to semi-clear in color whereupon the incandescent light can be removed and the crude mixture can be charged to a separation funnel where it can be washed sequentially with saturated sodium bicarbonate solution and water. The resulting clear oil can be dried over magnesium sulfate, filtered, and distilled to afford the 1,2-dibromo-1,1,2-trifluoroethane product.

A metal (Inconel® or Hastelloy®) tube reactor can be charged with the appropriate amount of activated carbon and heated by a furnace to about 150° C. To this tube, equal molar amounts of 1,1,2-trifluoroethene and elemental bromine can be fed at such a rate that they are consumed resulting in a semi-clear (reddish) liquid which can be collected in a flask cooled with dry ice. The liquid can be charged to a separation funnel where it can be washed sequentially with saturated sodium bicarbonate solution and water. The resulting clear oil can be dried over magnesium sulfate, filtered, and distilled to afford the 1,2-dibromo-1,1,2-trifluoroethane product.

Chemical production processes are also provided that can include providing a heterohalogenated olefin and a reducing reagent to within a reactor and reacting the olefin with the reducing agent within the reactor with at least the olefin being in the liquid phase during the reacting. The heterohalogenated olefin can include C₂CIF₃ and the reducing reagent can include H, such as H₂. A catalyst composition may also be provided to the reactor, the catalyst composition can include one or both of Pd and/or C, such as activated carbon. An organic media may be provided to the reactor as well. The media can include methanol, for example.

According to scheme (8) above, to a reactor equipped with an agitator, methanol can be added and cooled to about −10° C. To the methanol can be added a sufficient amount of a 10% (wt./wt.) palladium on activated carbon (Pd/AC) composition. At least about 1% (wt./wt.) of the amount of chlorotrifluoroethylene (CTFE) to be fed to the reactor can be a sufficient amount of the composition. The reactor can then be sealed, evacuated, and purged with hydrogen (H₂) twice. The reactor can then be heated to from about 30 to about 40° C. and then pressurized to 6 Kg/cm² of H₂. CTFE and H₂ can then be fed simultaneously to the reactor using a 20% molar ratio excess of H₂ to CTFE. The reactor pressure may increase, and when the pressure within the reactor reaches the desired operating pressure (1-12 Kg/cm²), the product trifluoroethylene (TriFE), CTFE, and H₂ can be removed which can result in a 50% conversion of CTFE to TriFE. A crude reaction mixture can assay as high as 70% TriFE by GC.

The crude reaction mixture can then be fed into another reactor (equipped with an agitator), and the reactor can be charged with elemental bromine (Br₂) at 50° C. while H₂ can be removed via a column connected to the reactor and fitted with a cooled condenser. Another crude reaction mixture can then be separated by distillation giving the desired 1,2-dibromo-1,1,2-trifluoroethylene (DBTFE) as a overhead condensate.

According to another embodiment, the perhalogenated olefin can be produced according to scheme (9) below from the starting material perchloroethene.

Claims

1. A chemical production process comprising reacting a metal comprising olefin to form a conjugated olefin.

2. The chemical production process of claim 1 wherein the metal comprising olefin comprises at least one element from groups 11 or 12 of the periodic table of elements.

3. The chemical production process of claim 2 wherein the one element is Zn.

4. The chemical production process of claim 1 wherein the metal comprising olefin comprises one or more of F, Cl, Br, and I.

5. The chemical production process of claim 4 wherein the metal comprising olefin is heterohalogenated.

6. The chemical production process of claim 4 wherein the metal comprising olefin is perhalogenated.

7. The chemical production process of claim 1 wherein the metal comprising olefin is a C-2 olefin.

8. The chemical production process of claim 7 wherein the metal comprising olefin comprises both F and Br.

9. The chemical production process of claim 7 wherein the metal comprising olefin comprises F, Br, and Zn.

10. The chemical production process of claim 7 wherein the metal comprising olefin is

11. The chemical production process of claim 1 wherein the conjugated olefin comprises one or more of F, Cl, Br, and I.

12. The chemical production process of claim 1 wherein the conjugated olefin is perhalogenated.

13. The chemical production process of claim 1 wherein the conjugated olefin is homohalogenated.

14. The chemical production process of claim 1 wherein the conjugated olefin is a C-4 olefin.

15. The chemical production process of claim 14 wherein the C-4 olefin is perhalogenated with F.

16. The chemical production process of claim 1 wherein the conjugated olefin is

17. The chemical production process of claim 1 wherein the reacting comprises exposing the metal-comprising olefin to a reactant mixture to form the conjugated olefin.

18. The chemical production process of claim 17 wherein the reactant mixture comprises one or more of Fe, Cu, Na, Mg, Ni, and Ag.

19. The chemical production process of claim 17 wherein the reactant mixture comprises a metal-halide composition.

20. The chemical production process of claim 19 wherein the metal halide composition comprises one or more of Fe, Cu, Na, Mg, Ni, Ag, F, Cl, Br, and I.

21. The chemical production process of claim 17 wherein the reactant mixture comprises a polar aprotic solvent.

22. The chemical production process of claim 17 wherein the reactant mixture comprises tetrahydrofuran.

23. The chemical production process of claim 17 wherein the exposing comprises:

providing the metal comprising olefin to within a reactor; and

providing the reactant mixture to within the reactor, wherein a temperature of the contents of the reactor is maintained during the providing of the catalyst mixture.

24. The chemical production process of claim 23 wherein:

the metal comprising olefin comprises

the reactant mixture comprises FeCl3; and

the temperature is less than about 70° C.

25. The chemical production process of claim 23 further comprising removing the conjugated olefin from the reactor.

26. The chemical production process of claim 25 wherein the removing comprises increasing the maintained temperature of the contents of the reactor.

27. The chemical production process of claim 26 wherein the increasing comprises at least about a 15% increase in the maintained temperature.

28. The chemical production process of claim 27 wherein the maintained temperature is about 70° C. and the increasing comprises increasing the temperature to about 90° C.

29. The chemical production process of claim 25 wherein:

the metal comprising olefin comprises

the reactant mixture comprises FeCl3;

the temperature is less than about 70° C.;

the conjugated olefin comprises and

 and

the increased temperature is greater than about 80° C.

30. The chemical production process of claim 25 further comprising purifying the conjugated olefin.

31. The chemical production process of claim 30 wherein the purifying comprises one or both of distilling and drying the conjugated olefin.

32. The chemical production process of claim 31 wherein the distilling comprises:

providing a product mixture comprising the conjugated olefin and by products to a distillation apparatus;

converting at least a portion of the mixture to the gas phase, the portion of the mixture comprising at least a portion of the conjugated olefin; and

recovering a distillate comprising the portion of the conjugated olefin, the distillate comprising less by-products than the product mixture.

33. The chemical production process of claim 31 wherein the drying comprises exposing a product mixture comprising the conjugated olefin to one or both of a 3 Å absorbent and a 13× molecular sieve.

34. The chemical production process of claim 33 wherein the product mixture is in the liquid phase during the exposing.

35. A chemical production process comprising reacting a heterohalogenated olefin to form a conjugated olefin.

36. The chemical production process of claim 35 wherein the heterohalogenated olefin is a C-2 olefin.

37. The chemical production process of claim 35 wherein the heterohalogenated olefin comprises F and one or more of Cl, Br, and I.

38. The chemical production process of claim 35 wherein the heterohalogenated olefin is

39. The chemical production process of claim 36 wherein the reacting comprises:

providing a reactor, the reactor being configured to expose a metal comprising mixture to the heterohalogenated olefin;

providing the metal comprising mixture to within the reactor; and

exposing the metal-comprising mixture to the heterohalogenated olefin to form a metal comprising olefin.

40. The chemical production process of claim 39 wherein the metal comprising mixture comprises at least one or more elements from groups 1, 2, 4, 8, 11, 12, and 14 of the periodic table of elements.

41. The chemical production process of claim 39 wherein the metal comprising mixture comprises Zn.

42. The chemical production process of claim 39 wherein the metal comprising mixture comprises a polar aprotic solvent.

43. The chemical production process of claim 39 wherein the metal comprising mixture comprises tetrahydrofuran.

44. The chemical production process of claim 39 wherein the providing the metal comprising mixture to within the reactor comprises:

providing a composition comprising a polar aprotic solvent and tetrahydrofuran to the reactor;

providing a metal to the reactor, the metal and composition forming the metal comprising mixture; and

heating the mixture to a temperature of from about 17° C. to about 120° C.

45. The chemical production process of claim 44 wherein the heating further comprises maintaining the mixture at a temperature of from about 60° C. to about 110° C.

46. The chemical production process of claim 39 further comprising conjugating the metal comprising olefin to form the conjugated olefin.

47. The chemical production process of claim 46 wherein:

the heterohalogenated olefin is

the reactant mixture is Fe;

the metal-comprising mixture is Zn;

the metal comprising olefin is

 and

the conjugated olefin is

48. A chemical production process comprising reacting a halogenated alkane to form a conjugated olefin.

49. The chemical production process of claim 48 wherein the halogenated alkane comprises one or more of F, Cl, Br, and I.

50. The chemical production process of claim 48 wherein the halogenated alkane is a C-2 alkane.

51. The chemical production process of claim 48 wherein the halogenated alkane is heterohalogenated.

52. The chemical production process of claim 48 wherein the halogenated alkane is C2HF3Br2.

53. The chemical production process of claim 52 wherein the halogenated alkane is

54. The chemical production process of claim 48 wherein the reacting comprises:

reacting the halogenated alkane to form a heterohalogenated olefin; and

reacting the heterohalogenated olefin to from the conjugated olefin.

55. The chemical production process of claim 54 wherein the reacting the halogenated alkane to form the heterohalogenated olefin comprises:

providing a reactor configured to expose the halogenated olefin to a reducing reagent mixture;

providing the reducing reagent mixture to within the reactor;

exposing the halogenated olefin to the reducing regent mixture to form the heterohalogenated olefin.

56. The chemical production process of claim 55 wherein the reactor comprises a nickel alloy.

57. The chemical production process of claim 55 wherein the reactor is glass lined.

58. The chemical production process of claim 55 wherein the reducing-reagent mixture comprises a base.

59. The chemical production process of claim 55 wherein the reducing reagent mixture comprises KOH and water.

60. The chemical production process of claim 55 wherein the reducing reagent mixture comprises 40% (wt./wt.) KOH.

61. A chemical production process comprising reacting a hydrohalogenated olefin to form a conjugated olefin.

62. The chemical production process of claim 61 wherein the hydrohalogenated olefin comprises one or more of F, Cl, Br, and I.

63. The chemical production process of claim 61 wherein the hydrohalogenated olefin is a C-2 olefin.

64. The chemical production process of claim 61 wherein the hydrohalogenated olefin is C2HF3.

65. The chemical production process of claim 61 wherein the hydrohalogenated olefin is

66. The chemical production process of claim 61 wherein the reacting comprises:

reacting the hydrohalogenated olefin to form a halogenated alkane; and

reacting the halogenated alkane to form the conjugated olefin.

67. The chemical production process of claim 61 wherein the reacting the hydrohalogenated olefin to form the halogenated alkane comprises:

providing a reactor configured to expose the hydrohalogenated olefin to a halogenating reagent;

providing the hydrohalogenated olefin to within a reactor; and

exposing the hydrohalogenated olefin to the halogenating reagent to form the halogenated alkane.

68. The chemical production process of claim 67 wherein halogenating reagent comprises one or more of F, Cl, Br, and I.

69. The chemical production process of claim 67 wherein:

the hydrohalogenated olefin is

the halogenated reagent is Br2; and

the halogenated alkane is

70. A chemical production process comprising:

providing a heterohalogenated olefin to within a reactor;

providing a reducing agent to within the reactor; and

reacting the olefin with the reducing agent within the reactor, at least the olefin being in the liquid phase during the reacting.

71. The chemical production process of claim 70 further comprising providing a catalyst composition to the reactor.

72. The chemical production process of claim 71 wherein the catalyst composition comprises one or both of Pd and C.

73. The chemical production process of claim 70 further comprising providing an organic media to the reactor.

74. The chemical production process of claim 73 wherein the organic media comprises as solvent.

75. The chemical production process of claim 73 wherein the organic media comprises methanol.

76. The chemical production process of claim 70 further comprising:

providing a catalyst composition to the reactor; and

providing an organic media to the reactor.

77. The chemical production process of claim 76 wherein:

heterohalogenated olefin is C2CIF3;

the reducing agent comprises H;

the catalyst composition comprises one or both of Pd and C; and

the organic media comprises methanol.

78. A production system comprising:

a first reactant reservoir configured to house a perhalogenated olefin;

a second reactant reservoir configured to house a catalyst mixture;

a first reactor coupled to both the first and second reservoirs, the first reactor configured to house a metal-comprising mixture and receive both the perhalogenated olefin from the first reactant reservoir and the reactant mixture from the second reactant reservoir; and

a product collection reservoir coupled to the first reactor and configured to house a conjugated olefin.

79. The production system of claim 78 wherein:

the perhalogenated olefin is

the reactant mixture is Fe;

the metal comprising mixture is Zn; and

the conjugated olefin is

80. The production system of claim 78 further comprising a second reactor coupled to both the product reservoir and the first reactant reservoir, the second reactor configured to receive at least one by-product from the product reservoir and react the by-product to form the perhalogenated olefin.

81. The production system of claim 80 wherein second reactor comprises both a third and a fourth reactor, the third reactor being coupled to the fourth reactor, wherein:

the third reactor is configured to react a hydrohalogenated olefin to form a halogenated alkane; and

the fourth reactor is configured to react the halogenated alkane to form a heterohalogenated olefin, wherein the by-product is one or both of the hydrohalogenated olefin and the halogenated alkane.

82. The production system of claim 81 wherein:

the hydrohalogenated olefin is

 and

the halogenated alkane is