Catalyst compositions for hydroformylation and methods of use thereof

Abstract

Disclosed are highly active cationic cobalt phosphine complexes, both mono- and bimetallic, that can catalyze hydroformylation reactions. The disclosed catalysts can be utilized in methods that provide reaction processes that are hundreds of times faster than high pressure HCo(CO)4 or phosphine-modified HCo(CO)3(PR3) catalysts and operate at considerably lower pressures and temperatures. Also disclosed are methods of hydroformylation using the described transition metal complexes. This abstract is intended as a scanning tool for purposes of searching in the particular art and is not intended to be limiting of the present disclosure.

Description

CROSS-REFERENCE TO RELATED APPLICATIONS[0001]This Application claims the benefit of U.S. Provisional Application No. 62 / 682,192, filed on Jun. 8, 2018, which is incorporated herein by reference in its entirety.BACKGROUND OF THE DISCLOSURE[0002]Hydroformylation is a reaction that converts alkenes, CO, and H2 into aldehyde products with linear and branched regioselectivities. Side reactions include alkene isomerization and hydrogenation. ExxonMobil has a hydroformylation plant in Baton Rouge that uses the well-known HCo(CO)4 catalyst system, which was originally discovered by Otto Roelen in Germany in 1938. HCo(CO)4 is considered the most active cobalt catalyst system known, but has a major weakness in that it decomposes to inactive cobalt metal unless high enough pressures of CO gas are used. As the temperature of the reaction increases, the CO partial pressure used must increase logarithmically in order to keep HCo(CO)4 from decomposing to cobalt metal. ExxonMobil runs their hydrofo...

AI Technical Summary

Benefits of technology

The patent is about a new type of catalyst that can be used to speed up chemical reactions called hydroformylation. These catalysts are made up of cationic transition metal phosphine complexes, which are much faster and work at lower pressures and temperatures than existing catalysts. The patent also describes methods for making these new catalysts and using them to make certain compounds. Overall, the patent provides a way to make these new catalysts and use them to improve the efficiency of hydroformylation reactions.

Problems solved by technology

HCo(CO)4 is considered the most active cobalt catalyst system known, but has a major weakness in that it decomposes to inactive cobalt metal unless high enough pressures of CO gas are used.

One moderately serious problem with the Shell catalyst is that it also hydrogenates alkene into alkane, consuming about 15-20% of the valuable alkene starting material to semi-worthless alkane.

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