Process for preparing carboxylic acids

Abstract

Aliphatic primary alcohols, including aliphatic primary alcohols possessing one or more oxygen, nitrogen and/or phosphorus heteroatoms that may be atoms substituting for carbon atoms in the alkyl group or component atoms of substituents on the alkyl group, were converted into salts of carboxylic acids by contacting an alkaline aqueous solution of the primary alcohol with a catalyst comprising cobalt, copper, and at least one of cerium, iron, zinc, and zirconium. Diethanolamine, for example, was converted to sodium iminodiacetate by treatment in an aqueous medium containing sodium hydroxide with a catalyst that was obtained by reducing a mixture of cobalt, copper, and zirconium oxides with hydrogen.

What is claimed is:  
     
         1 . A process for the preparation of a salt of an aliphatic carboxylic acid compound that is unsubstituted or possesses one or more substituents that contain one or more oxygen, nitrogen and/or phosphorus atoms, which process comprises contacting a primary aliphatic alcohol compound that is unsubstituted or possesses one or more substituents that contain one or more oxygen, nitrogen and/or phosphorus atoms with a catalyst comprising, on a contained metals basis, about 10 to about 90 mole percent cobalt, about 8 to about 88 mole percent copper, and about 1 to about 16 mole percent of a third metal selected from cerium, iron, zinc, and zirconium, or mixtures thereof, in an alkaline aqueous medium, in the effective absence of oxygen, and at a temperature of about 120° C. to about 200° C.  
     
     
         2 . A process according to    claim 1    wherein the alcohol compound possesses one or more substituents that contain one or more oxygen and/or nitrogen heteroatoms.  
     
     
         3 . A process according to    claim 1    wherein the alcohol compound has the formula:  
       X—CH(R)CH 2 OH  
       wherein 
 X represents H, CH 3 , OH, O(C 1 -C 4 )alkyl, OCH(R)CH(R)OH, OCH(R)CO 2 H, OCH(R)CH(R)NH 2 , OCH(R)CH(R)NH(C 1 -C 4 )alkyl, OCH(R)CH(R)N((C 1 -C 4 )alkyl) 2 , OCH(R)CH(R)N(CH(R)CH 2 OH) 2 , OCH(R)CH(R)N(CH(R)CO 2 H) 2 , NH 2 , NH(C 1 -C 4 )alkyl, NHCH 2 P(O)(OH) 2 , N((C 1 -C 4 )alkyl) 2 , NHCH(R)CH(R)OH, N(CH(R)CH(R)OH) 2 , NHCH(R)CO 2 H, N(CH(R)CO 2 H) 2 , N(C 1 -C 4 )alkyl)(CH(R)CH(R)OH), N(CH(R)CH(R)OH)(CH 2 P(O)(OH) 2 ), N(CH(R)CO 2 H)(CH 2 P(O)(OH) 2 ), N(C 1 -C 4 )alkyl)(CH(R)CO 2 H), N(CH(R)CH(R)OH) (CH(R)CO 2 H), N(CH 2 CH 2 OH)CH 2 CH 2 N(CH 2 CH 2 OH) 2 , or N(CH 2 CH 2 OH)CH 2 CH 2 N(CH 2 CH 2 OH)N(CH 2 CH 2 OH) 2 ; and  
 each R independently represents H or CH 3 .  
 
     
     
         4 . A process according to    claim 1    wherein the alcohol compound is selected from ethanolamine, 2-aminopropanol, N-methylethanolamine, N-phosphonomethylethanolamine, diethanolamine, N-methyldiethanolamine, N-phosphonomethyldiethanolamine, N-(2-hydroxyethyl)glycine, N,N-di(2-hydroxyethyl)glycine, N,N-di(2-hydroxyethyl)alanine, triethanolamine, 2-(2-aminoethoxy)ethanol, diethylene glycol, N-(2-(2-hydroxyethoxy)ethyl)diethanolamine, N-(2-(2-hydroxyethoxy)ethyl)iminodiacetic acid, and N,N,N′,N′-tetra(2-hydroxyethyl)ethylenediamine.  
     
     
         5 . A process according to    claim 4    wherein the alcohol compound is diethanolamine or a derivative thereof and the compound prepared is a salt of iminodiacetic acid or a derivative thereof.  
     
     
         6 . A process according to    claim 4    wherein the alcohol compound is ethanolamine or a derivative thereof and the compound prepared is a salt of glycine or a derivative thereof.  
     
     
         7 . A process according to    claim 1    wherein the catalyst contains about 25 to about 70 mole percent cobalt, about 25 to about 70 mole percent copper, and about 2 to about 14 mole percent of the third metal, on the basis of the total metal content.  
     
     
         8 . A process according to    claim 7    wherein the catalyst contains about 30 to about 50 mole percent cobalt, about 45 to about 65 mole percent copper, and about 3 to about 10 mole percent of the third metal, on the basis of the total metal content.  
     
     
         9 . A process according to    claim 1    wherein the third metal is zirconium.  
     
     
         10 . A process according to    claim 9    wherein the catalyst comprises about 38 mole percent cobalt, about 57 mole percent copper, and about 5 mole percent zirconium on the basis of the total metal content.  
     
     
         11 . A process according to    claim 1    wherein the temperature is maintained at about 140° C. to about 200° C.  
     
     
         12 . A process according to    claim 1    wherein the medium contains an alkali metal hydroxide in the amount of at least about one mole to about 2 moles per mole of primary alcohol moiety undergoing conversion to carboxylic acid group.  
     
     
         13 . A process according to    claim 1    wherein the alkali metal hydroxide is sodium hydroxide.  
     
     
         14 . A process according to    claim 1    carried out in a batch reactor system.  
     
     
         15 . A process according to    claim 1    carried out in a continuous reactor system.  
     
     
         16 . A process for the preparation of an aliphatic carboxylic acid compound that is unsubstituted or possesses one or more substituents that contain one or more oxygen, nitrogen and/or phosphorus atoms, which process comprises contacting a primary aliphatic alcohol compound that is unsubstituted or possesses one or more substituents that contain one or more oxygen, nitrogen and/or phosphorus atoms with a catalyst comprising, on a contained metals basis, about 20 to about 90 mole percent cobalt, about 8 to about 72 mole percent copper, and about 1 to about 16 mole percent of a third metal selected from cerium, iron, zinc, and zirconium, or mixtures thereof, in an alkaline aqueous medium, in the effective absence of oxygen, and at a temperature of about 120°C. to about 200° C., and, thereafter acidifying with a strong acid.  
     
     
         17 . A process according to    claim 16    wherein the alcohol compound possesses one or more substituents that contain one or more oxygen and/or nitrogen heteroatoms.  
     
     
         18 . A process according to    claim 16    wherein the alcohol compound has the formula:  
       X—CH(R)CH 2 OH  
       wherein 
 X represents H, CH 3 , OH, O(C 1 -C 4 )alkyl, OCH(R)CH(R)OH, OCH(R)CO 2 H, OCH(R)CH(R)NH 2 , OCH(R)CH(R)NH(C 1 -C 4 )alkyl, OCH(R)CH(R)N((C 1 -C 4 )alkyl) 2 , OCH(R)CH(R)N(CH(R)CH 2 CH) 2 , OCH(R)CH(R)N(CH(R)CO 2 H) 2 , NH 2 , NH(C 1 -C 4 )alkyl, NHCH 2 P(O)(OH) 2 , N((C 1 -C 4 )alkyl) 2 , NHCH(R)CH(R)OH, N(CH(R)CH(R)OH) 2 , NHCH(R)CO 2 H, N(CH(R)CO 2 H) 2 , N(C 1 -C 4 )alkyl)(CH(R)CH(R)OH), N(CH(R)CH(R)OH)(CH 2 P(O)(OH) 2 ), N(CH(R)CO 2 H)(CH 2 P(O)(OH) 2 ), N(C 1 -C 4 )alkyl)(CH(R)CO 2 H), N(CH(R)CH(R)OH)(CH(R)CO 2 H), N(CH 2 CH 2 OH)CH 2 CH 2 N(CH 2 CH 2 OH) 2 , or N(CH 2 CH 2 OH)CH 2 CH 2 N(CH 2 CH 2 OH)N(CH 2 CH 2 OH) 2 ; and  
 each R independently represents H or CH 3 .  
 
     
     
         19 . A process according to    claim 16    wherein the alcohol compound is selected from ethanolamine, 2-aminopropanol, N-methylethanolamine, N-phosphonomethylethanolamine, diethanolamine, N-methyldiethanolamine, N-phosphonomethyldiethanolamine, N-(2-hydroxyethyl)glycine, N,N-di(2-hydroxyethyl)glycine, N,N-di(2-hydroxyethyl)alanine, triethanolamine, 2-(2-aminoethoxy)ethanol, diethylene glycol, N-(2-(2-hydroxyethoxy)ethyl)diethanolamine, N-(2-(2-hydroxyethoxy)ethyl)iminodiacetic acid, and N,N,N′,N′-tetra(2-hydroxyethyl)ethylenediamine.  
     
     
         20 . A process according to    claim 19    wherein the alcohol compound is diethanolamine or a derivative thereof and the compound prepared is iminodiacetic acid or a derivative thereof.  
     
     
         21 . A process according to    claim 19    wherein the alcohol compound is ethanolamine or a derivative thereof and the compound prepared is glycine or a derivative thereof.  
     
     
         22 . A process according to    claim 16    wherein the catalyst contains about 30 to about 50 mole percent cobalt, about 45 to about 65 mole percent copper, and about 3 to about 10 mole percent of the third metal, on the basis of the total metal content.  
     
     
         23 . A process according to    claim 16    wherein the third metal is zirconium.  
     
     
         24 . A process according to    claim 23    wherein the catalyst comprises about 38 mole percent cobalt, about 57 mole percent copper, and about 5 mole percent zirconium on the basis of the total metal content.  
     
     
         25 . A process according to    claim 16    wherein the temperature is maintained at about 140° C. to about 200° C.  
     
     
         26 . A process according to    claim 16    wherein the medium contains an alkali metal hydroxide in the amount of at least about one mole to about 2 moles per mole of primary alcohol moiety undergoing conversion to carboxylic acid group.  
     
     
         27 . A process according to    claim 16    wherein the alkali metal hydroxide is sodium hydroxide.  
     
     
         28 . A process according to    claim 16    wherein the strong acid is hydrochloric acid or sulfuric acid.  
     
     
         29 . A process according to    claim 16    wherein the dehydrogenation reaction is carried out in a batch reactor system.  
     
     
         30 . A process according to    claim 16    wherein the dehydrogenation reaction is carried out in a continuous reactor system.