Triaryl Phosphate Ester Process Reducing TPP Content
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Solution Overview
Problem
Current processes for preparing triaryl phosphate esters result in high triphenyl phosphate (TPP) content, use expensive reagents, have low overall yields, and generate excessive waste streams, making them undesirable for environmental and economic reasons.
Innovation Solution
A process involving the reaction of phosphorous oxyhalide with a (C1-C15-alkyl)phenol, followed by reaction with phenol, using a stoichiometric excess of (C1-C15-alkyl)phenol to achieve high yields and low TPP content, with reduced distillation and evaporation steps, and employing Lewis acid catalysts like MgCl2 to enhance reaction efficiency.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Quantity of substance
If conventional processes are used to prepare triaryl phosphate esters, then the product can be obtained, but the triphenyl phosphate (TPP) content is high (30-45 wt.%)
Solution Approach 1:
The patent changes the stoichiometric parameters of the reaction by using a specific molar ratio of phenol to phosphorous oxyhalide (1.3-1.6:1) and controlling the reaction temperature profile. This parameter optimization shifts the product distribution to minimize TPP formation while maintaining high yields of desired triaryl phosphate esters, reducing TPP content from conventional 30-45 wt.% to significantly lower levels.
Solution Approach 2:
The patent performs preliminary alkylation of phenol with alkylene oxides before the phosphorylation step. This pre-modification of the phenol structure controls the subsequent reaction pathway with phosphorous oxyhalide, directing it to form desired alkylated triaryl phosphate esters rather than excessive TPP, thereby preventing harmful substance formation at the source.
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
The process achieves triaryl phosphate ester compositions with TPP content of 0.5 wt.% or less, high overall yields above 95%, and maintains high phosphorous content, using common and cost-effective starting materials while minimizing waste and solvent use.
Implementation Method 1
reacting a phosphorous oxyhalide with a (C1-C15-alkyl)phenol to obtain a first product
Implementation Method 2
reacting the first product with phenol to obtain a triaryl phosphate ester composition
Implementation Method 3
employing Lewis acid catalysts like MgCl2 to enhance reaction efficiency
Data Source
AI summary
The invention relates to a process for the preparation of a triaryl phosphate ester composition comprising a. reacting a phosphorous oxyhalide with a (C1-C15-alkyl)phenol to obtain a first product; b. reacting the first product with phenol to obtain a triaryl phosphate ester composition; wherein in step a., for every mol of phosphorous oxyhalide 1.3 to 1.6 mols of (C1-C15-alkyl)phenol are used. The invention also relates to a triaryl phosphate ester composition obtainable according to the process of the invention.