Bayer Aktiengesellschaft

Carsten Hesse

Johann Rechner

Hans-Josef Buysch

Ursula Jansen

Dieter Kaufmann

Eberhard Zirngiebl

Kaspar Hallenberger

Ulrich Notheis

Claus-Peter Reisinger

Hans-Peter Wirges

Martin Friedrich

Rob Eek

Thomas Himmler

Paul Wagner

Steffen Kuhling

Gottfried Zaby

Jorg-Dietrich Jentsch

Reinhard Schomacker

J&ouml;rg-Dietrich Jentsch

Joachim Dohm

A process for preparing a formulation containing tetrabutylammonium phenolate and phenol is disclosed. The process entails combining a solution of tetrabutylammonium bromide in phenol with a solution of sodium phenolate to form a mixture, excess phenol is removed by distillation, and sodium bromide is filtered off. The formulation, that contains tetrabutylammonium phenolate and phenol in a weight ratio of 40:60 to 70:30, has a solidification point of less than 25&#xb0; C. and finds use as a catalyst constituent.

Liquid tetrabutyl ammonium phenolate formulation

A process for the work up of a reaction mixture obtained from the preparation of diaryl carbonate by direct carbonylation of aromatic hydroxy compounds is disclosed. The process entails obtaining a reaction mixture that contains diaryl carbonate, aromatic hydroxy compound, water, base and quaternary salt, separating the mixture in a distillation apparatus having only one theoretical separation stage into a liquid phase and a gas phase and recycling the liquid phase without further work up to the reaction step of the direct carbonylation.

Method for reprocessing reaction mixtures containing diaryl carbonate

In the process for preparing an aromatic carbonate from an aromatic hydroxy compound, CO and O in the presence of a quaternary salt and a base using a platinum metal catalyst and a cocatalyst, use is advantageously made of supported catalysts containing, in the reaction-ready state, (i) a platinum metal, a platinum metal halide or a platinum metal halide complex and (ii) a metal compound acting as cocatalyst from groups IB, IIB, IIIA, IIIB, IVA, IVB, VB, VIB, VIIB, the iron group (atomic numbers 26-28) or the rare earth metals (atomic numbers 58-71) of the Periodic Table of the Elements (Mendeleev), each in an amount of 0.01-15% by weight, calculated as metal and based on the total weight of the catalyst.

Supported catalysts containing a platinum metal and process for preparing diaryl carbonates

A process for the work up of reaction mixtures containing diaryl carbonate, aromatic hydroxy compound, water, base and quaternary salt, which are obtained in the preparation of diaryl carbonates by direct carbonylation of aromatic hydroxy compounds, is described. In the process of the present invention an adduct of diaryl carbonate and aromatic hydroxy compound is crystallized from the reaction mixture. A distillate comprising aromatic hydroxy compound is removed from the liquid phase either prior to or after crystallization of the adduct of diaryl carbonate and aromatic hydroxy compound. The liquid phase remaining after the crystallization and distillation steps may be recycled, without further work up, back to the direct carbonylation process step by which the diaryl carbonate is initially prepared.

Described is a process for preparing an aromatic carbonate, e.g., diphenyhl carbonate, in which an aromatic hydroxy compound, e.g., phenol, is reacted with carbon monoxide and oxygen in the resence of a supported catalst prepared by a sol-gel process, a quatermary ammonium or phosphonium salt and a base. The sol-gel supported catlyst comprises: (i) a first metal oxide selected from the group consisting of silicon oxide, aluminum oxide, titanium oxide, zirconium oxide and mixtures thereof; (ii) a second metal oxide selected from the group consisting of oxides of the elements of groups 4, 5, 6, 7, 11, 12, 13, 14, the iron group (atomic numbers 26 to 28), the rare-earth metals (atomic numbers 58 to 71) and mixtures thereof; and (iii) a metal selected from the group consisting of platinum metals, compounds of platinum metals (atomic numbers 44 to 46 and 77 and 78) and mixtures thereof. The sol-gel supported catlyst is aged, dried and optionally annealed prior to use in the process of the present invention.

Catalysts containing a platinum group metal and produced in a sol-gel method, as well as a method for producing diarylcarbonates

A platinum metal-containing supported catalyst in which the support contains mixed oxides of metals, transition metals and semiconductor elements, which can act as redox catalysts under the reaction conditions is disclosed. Also disclosed is the preparation of these catalysts and their use in a process for preparing diaryl carbonates.

Supported catalysts containing a platinum group metal and method for producing diarylcarbonates

The invention relates to a method for producing and purifying tetrabutyl ammonium phenolate diphenol adduct by reacting an alkali phenolate with tetrabutyl ammonium salts in an aqueous phase and subsequently precipitating the adduct by adding phenol.

Method for producing tetrabutyl ammonium phenolate diphenol adduct

Platinum metal-containing catalyst systems, which comprise at least one platinum metal, a co-catalyst and other salts, and which are used for the production of diaryl carbonates by the oxidative reaction of aromatic hydroxy compounds with carbon monoxide, can be reactivated by treating the deactivated catalyst system in the liquid phase with an oxidising agent, removing the excess oxidising agent, and reacting the reactivated catalyst system with a carboxylate or diketonate.

Process for reactivating catalyst systems containing a platinum group

In the process for preparing an aromatic carbonate from an aromatic hydroxy compound, CO and O.sub.2 in the presence of a quaternary salt and a base, use is advantageously made of supported catalysts which, in the reaction-ready state, contain a platinum metal, a platinum metal compound or a complex containing a platinum metal compound on a support comprising a metal oxide whose metal can occur in a plurality of oxidation states.

Supported catalysts containing a platinum metal and process for

Catalyst systems with a content of a platinum-group-metal catalyst, a co-catalyst, a quaternary salt and a base for the oxidative carbonylation of aromatic hydroxy compounds to the corresponding diaryl carbonates are according to the invention obtained as a mother liquor by suspension crystallization and can be returned into the carbonylation reaction or worked up to valuable materials. The crystallizate, which consists predominantly of diaryl carbonate and the parent aromatic hydroxy compound, is worked up to pure diaryl carbonate and pure hydroxy compound.

Recovery of catalyst systems from diaryl carbonate-containing reaction

The present invention relates to a process for producing diaryl carbonates by the reaction of an aromatic hydroxy compound (e.g. phenol) with carbon monoxide and oxygen in the presence of a catalyst, a co-catalyst, a quaternary salt and a base, which is characterised in that the reaction is conducted in a melt comprising the diaryl carbonate and the hydroxy compound on which the carbonate is based, and further diaryl carbonate is optionally added to this reaction mixture before work-up.

Process for producing diaryl carbonates

Catalyst systems with a content of a platinum-group-metal catalyst, a co-catalyst, a quaternary salt and a base for the oxidative carbonylation of aromatic hydroxy compounds to the corresponding diaryl carbonates are obtained according to the invention as a residual melt by melt crystallization and can be returned into the carbonylation reaction or worked up to valuable materials. The melt crystallizate, which consists predominantly of diaryl carbonate and the parent aromatic hydroxy compound, is worked up to pure diaryl carbonate and pure hydroxy compound.

Recovery of catalyst systems from diarylcarbonate-containing reaction

In the process for the production of diaryl carbonates by oxidative carbonylation of the underlying aromatic hydroxy compounds in the presence of a catalyst containing a platinum group metal, a co-catalyst, a quaternary salt and a base, the catalyst is used as a supported catalyst in a stationary arrangement or in the fluid phase and the reaction is performed in the condensed phase. The co-catalyst is preferably also attached to the support.

Process for the continuous production of diaryl carbonates

The invention relates to a process for preparing a diaryl carbonate by oxidative carbonylation of the basic aromatic hydroxy compound, in which the aromatic hydroxy compound is the one which is eliminated during melt polycondensation of this diaryl carbonate with a bisphenol. Accordingly the invention also relates to the preparation of polycarbonates by melt polycondensation of diaryl carbonates with bisphenols in which the aromatic hydroxy compounds which is eliminated is used again to prepare the diaryl carbonate. In the event that the aromatic hydroxy compound eliminated is also the basic unit in the bisphenol used, proportions of it may be used to prepare both the diaryl carbonate and the bisphenol.

Process for preparing diaryl carbonates and the polycarbonates

Diaryl carbonate and an aromatic hydroxy compound are simultaneously separated from a crude reaction mixture for producing diaryl carbonates by oxidative carbonylation of the aromatic hydroxy compound and containing the diaryl carbonate and excess hydroxy compound together with the catalyst system, consisting of a noble-metal catalyst, co-catalyst, quaternary salt and a base. The crude reaction mixture is mixed with a covalent aprotic extraction agent, a phase separation is carried out into a donor phase containing the catalyst system and a recipient phase containing the diaryl carbonate and the hydroxy compound in concentrated form, and the diaryl carbonate and the hydroxy compound are isolated from the recipient phase.

Growing community of inventors

Krefeld, Germany

Carsten Hesse