Preparation of efficient REPO and LAPO catalysts

Abstract

A method of ensuring the production of efficient lanthanum phosphate catalysts (LAPO's) and rare earth phosphate catalysts (REPO's), and methods of alkoxylation using said efficient catalysts.

1 - 188 . (canceled)  
     
     
         189 . A method for alkoxylation of organic compounds, said method comprising: 
 reacting one or more carbonate salts of one or more lanthanum series metals with a source of phosphate under conditions effective to produce one or more efficient lanthanum phosphate catalysts comprising increased activity for said alkoxylation compared to activity of substantially the same catalyst produced by reacting one or more salts other than carbonate salts of said lanthanum series metals with said source of phosphate;    reacting one or more alkylene oxides and one or more organic compounds comprising active hydrogen in the presence of a catalytically effective amount of said efficient lanthanum phosphate catalyst.    
     
     
         190 . The method of  claim 189  wherein said increased activity for said alkoxylation is at least 1.5 times activity of substantially the same catalyst produced by reacting one or more salts other than carbonate salts of said rare earth metals with said source of phosphate.  
     
     
         191 . The method of  claim 189  wherein said increased activity for said alkoxylation is at least 2 times activity of substantially the same catalyst produced by reacting one or more salts other than carbonate salts of said rare earth metals with said source of phosphate.  
     
     
         192 . The method of  claim 189  wherein said increased activity for said alkoxylation is at least 3 times activity of substantially the same catalyst produced by reacting one or more salts other than carbonate salts of said rare earth metals with said source of phosphate.  
     
     
         193 . The method of  claim 190  wherein said alkylene oxides comprise one or more vicinal alkylene oxides.  
     
     
         194 . The method of  claim 190  wherein said catalytically effective amount of carbonate salt derived catalyst is about 0.006% w or more.  
     
     
         195 . The method of  claim 190  wherein said catalytically effective amount of carbonate salt derived catalyst is from about 0.013 to about 3.33% w.  
     
     
         196 . The method of  claim 190  wherein said catalytically effective amount of carbonate salt derived catalyst is from about from about 0.025 to about 0.5% w.  
     
     
         197 . The method of  claim 190  wherein, if a quantity (x) of a carbonate derived catalyst of a given rare earth or lanthanum series metal or mixture is used, and the same quantity (x) of the same catalyst which is not carbonate derived is used to catalyze a reaction under the same conditions, then the reaction catalyst by the carbonate-derived catalyst will take about ⅔ or less, preferably about ½ or less, more preferably about ¼ or less of the reaction time required to achieve the same level of catalysis by the non-carbonate salt derived catalyst.  
     
     
         198 . The method of  claim 194  wherein said one or more organic compounds comprising active hydrogen comprises primary active hydrogen.  
     
     
         199 . The method of claim  187  wherein said one or more organic compounds comprising active hydrogen comprises primary active hydrogen.  
     
     
         200 . The method of  claim 194  wherein said one or more organic compounds comprising active hydrogen comprises one or more compound selected from the group consisting of alkanols, phenols, thiols, amines, polyols, and carboxylic acids.  
     
     
         201 . The method of  claim 197  wherein said one or more organic compounds comprising active hydrogen comprises one or more compound selected from the group consisting of alkanols, phenols, thiols, amines, polyols, and carboxylic acids.  
     
     
         202 . The method of  claim 197  wherein said one or more organic compounds comprising active hydrogen is an alkoxylate product of a previous alkoxylation of an active hydrogen containing compound.  
     
     
         203 . The method of  claim 194  wherein said one or more alkylene oxides are selected from the group consisting of ethylene oxide, propylene oxide, and mixtures thereof.  
     
     
         204 . The method of  claim 197  wherein said one or more alkylene oxides are selected from the group consisting of ethylene oxide, propylene oxide, and mixtures thereof.  
     
     
         205 . The method of  claim 190  wherein said one or more alkylene oxides comprises ethylene oxide and said one or more organic compounds comprising active hydrogen comprises a C 1  to C 30  primary alkanol.  
     
     
         206 . The method of  claim 194  wherein said one or more alkylene oxides comprises ethylene oxide and said one or more organic compounds comprising active hydrogen comprises a C 1  to C 30  primary alkanol.  
     
     
         207 . The method of  claim 197  wherein said one or more alkylene oxides comprises ethylene oxide and said one or more organic compounds comprising active hydrogen comprises a C 1  to C 30  primary alkanol.  
     
     
         208 . The method of  claim 190  wherein said catalyst consists essentially of salts having the formula LPO 4 .  
     
     
         209 - 227 . (canceled)