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1. EP3230248 - HYDROFORMYLATION PROCESS

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Claims

1. A continuous hydroformylation process comprising: (a) removing a reaction fluid from a reactor, wherein the reaction fluid is obtained by contacting CO, H 2, an olefin and a catalyst comprising rhodium and an organophosphite ligand in a reaction zone under hydroformylation reaction conditions to produce an aldehyde product in the reaction fluid; (b) sending the reaction fluid to a vaporizer; (c) separating the reaction fluid in the vaporizer to produce a catalyst-containing liquid stream and a gas phase stream; and (d) maintaining an average CO partial pressure in the vaporizer of greater than 110 kPa (16 psia) by adding fresh CO to the vaporizer, wherein the hydroformylation process employs a metal organophosphorous ligand complex catalyst, the ligand being selected from monoorganophosphite, diorganophosphite, triorganophosphite and organopolyphosphite compounds.
  2. A continuous hydroformylation process comprising:

(a) feeding a reaction fluid comprising one or more products, one or more heavy by-products, a transition metal-organophosphite ligand complex catalyst, one or more unconverted reactants, and one or more inert lights into a vaporizer; wherein the reaction fluid is obtained by contacting CO, H2, an olefin and a catalyst comprising rhodium and an organophosphite ligand in a reaction zone under hydroformylation reaction conditions to produce an aldehyde product in the reaction fluid;

(b) removing from the vaporizer an overhead gas stream comprising one or more products, one or more unconverted reactants, one or more inert lights, and a portion of the heavy by-products, and feeding said overhead gas stream into a condenser;

(c) removing from the condenser a condenser overhead gas stream comprising one or more unconverted reactants and one or more inert lights;

(d) recycling at least a portion of said condenser overhead gas stream to the vaporizer;

(e) introducing to the vaporizer, in addition to the condenser overhead gas stream, a gas stream comprising CO, such that the average CO partial pressure in the vaporizer is greater than 110 kPa (16 psia); and

(f) removing as a tails stream from the vaporizer, a liquid recycle catalyst stream comprising the transition metal-organophosphite ligand complex catalyst and the balance of the heavy by-products.


  3. The process of any of the preceding claims wherein the average CO partial pressure in the vaporizer is at least 138 kPa (20 psia).
  4. The process of any of the preceding claims wherein the average CO partial pressure in the vaporizer is at least 172 kPa (25 psia).
  5. The process of any of the preceding claims wherein the process outlet temperature of the vaporizer is at least 80 °C.
  6. The process of any of the preceding claims wherein, in the vaporizer, the H 2 partial pressure is from 0.7 kPa (0.1 psia) to less than half the CO partial pressure.
  7. The process of any of the preceding claims wherein, in the vaporizer, the H 2 partial pressure is from 0.7 kPa (0.1 psia) to no more than 10% of the CO partial pressure.
  8. The process of any of the preceding claims wherein the catalyst is a transition metal-organophosphite ligand complex catalyst, wherein the ligand comprises an organomonophosphite ligand.
  9. The process of any of the preceding claims, further comprising maintaining an average H 2 partial pressure in the vaporizer of less than 14 kPa (2 psia).
  10. The process of any of the preceding claims, further comprising sending the reaction fluid to a flash vessel prior to sending the reaction fluid to the vaporizer.