Hydroformylation
CROSS-REFERENCE TO CO-PENDING APPLICATION 
     This application is a continuation-in-part of coassigned U.S. application Ser. No. 366,387 filed June 4, 1973, and now abandoned. 
    
    
     BACKGROUND OF THE INVENTION 
     This invention is concerned with a method of processing the hydroformylation reaction product and catalyst to improve the overall economics and yield of the reaction. 
     This reaction and several modifications thereof are well-known in the art for producing aldehydes and/or primary &#34;oxo&#34; alcohols from olefins. The oxo alcohols find utility as solvents, lubricants, herbicides, odorants, and as intermediates in the manufacture of various plastics. 
     In the general case, the subject reaction involves the steps of contacting an olefinic hydrocarbon in the liquid phase with carbon monoxide and hydrogen at a temperature in the range of about 100° to 300° C. under a pressure of 1 to 2000 psig in the presence of a catalyst consisting of cobalt in complex combination with carbon monoxide and a trialkylphosphine ligand. The ratio of catalyst to olefin can be from about 1:1000 to about 10:1. The ratio of hydrogen to carbon monoxide can be from about 1:1 to about 10:1.  The reactants include any aliphatic or cycloaliphatic compounds having at least one ethylenic carbon bond and nonhydrocarbons having such bonds. However, the main use of the reaction is the hydroformylation of olefins to form aldehydes and alcohols having one more carbon atom than the olefinic compound. The reaction can be illustrated by the following equation: ##STR1## 
     STATEMENT OF THE PRIOR ART 
     The prior art to which this invention relates, is aware, inter alia, of U.S. Pat. Nos. 2,779,802; 2,609,337; 2,683,752, 2,696,506; and of British Pat. No. 1,071,399.  The first of these describes an improvement in the oxo process wherein an inert vapor is passed through the intermediate aldehydic product containing dissolved cobalt catalyst to facilitate its separation from the carbinol product. In U.S. Pat. No. 2,609,337 is described a flash distillation process for the treatment of a reaction product containing an aldehyde and a cobalt catalyst. Said process allows for extensive build up of catalyst residue on the heated surface; prolonged exposure of the catalyst residue to elevated temperature and increased catalyst decomposition. The process is concerned with aldehyde recovery but does not achieve reduced catalyst decomposition or catalyst recycle. In U.S. Pat. No. 2,683,752 the inventors disclose a method for extracting phenols from waste aqueous solutions by treatment with at least a fraction of the formylation bottoms of an oxo process. U.S. Pat. No. 2,696,506 shows an improved oxo process wherein the product is heated to decompose cobalt carbonyl into carbon monoxide and cobalt which deposits on a heated drum. In British Pat. No. 1,071,399, the oxo process is allowed to occur with the cobalt carbonyl catalyst solution being added to the hydroformylation reactor as a thin film. 
     SUMMARY OF THE INVENTION 
     In this process, the crude oxo product is metered to a thin film evaporator wherein the distillate, containing olefins, paraffins, aldehydes and alcohols, is separated from the residue containing catalyst complex and heavy ends by contacting with a heated surface for a very short residence time of 5 to 55 seconds. The distillate is collected and further vacuum fractionated to remove unreacted olefins and mixed paraffins from product aldehydes and alcohols. The aldehydes and alcohols fraction can then be hydrogenated and sent to an alcohol purification section. The entire residue containing the catalyst can be recycled directly to the oxo reactor, or mixed with fresh catalyst while being recycled to the oxo reactor; or a major portion of the residue (about 90%) can be recycled to the oxo reactor while the remaining residue portion proceeds to the catalyst recovery zone wherein fresh makeup catalyst is prepared and routed to the oxo reactor. 
     The present process centers around the use of a wiped film evaporator which separates aldehydes, alcohols, olefins and paraffins from the catalyst bottoms. The evaporator has rotating wiper blades which produce mechanically a thin film and continuously wipe this film on a heated surface. This mechanical wiping action provides a more rapid removal of the catalyst residue or bottoms and eliminates dependence on gravity flow. The process thus allows for: minimal build up of catalyst residue, due to the continuous wiping action; reduced catalyst decomposition and rapid continuous processing. 
     In the practice of the present process, the crude oxo product is charged to a thin film evaporator. A 2 inch diameter Turbo-Film Processor having 0.35 sq. foot evaporative surface was used at a rate ranging from 25 to 150 cc/hour (preferably 60 cc/hour). Distillation temperatures from 150° to 500° F. (preferably from 200° to 250° F.) and pressures from 0.001 to 50 mm Hg (preferably from 0.001 to 10 mm) can be employed. The catalyst complex can be any metal metal carbonyls or metal complexes capable of catalyzing the oxo reaction (preferably dicobalt octacarbonyl in complex combination with tri-n-butylphosphine). The cobalt source can be dicobalt octacarbonyl, the cobalt salt of an organic salt (preferably cobalt stearate), or cobalt itself. The ligand can be any organophosphine (preferably tri-n-butylphosphine), - phosphite, - phosphate or phosphonate or other ligands used for complexing oxo catalysts. 
     The completeness of separation of the crude reaction product from the catalyst-heavy ends is dependent on the thin film distillation temperature, pressure and rate. Thus a rate sufficient to effect substantially complete separation at the operating temperature and pressure should be used. 
     The process is adaptable to a wide range of olefins by proper selection of thin film evaporation conditions. Thus C 2  -C 30  alpha, internal and mixed olefins can be treated by the present process. These olefins include those derived by dehydrogenation of paraffins, wax cracking, olefin polymerization and the like. 
     In a commercial process the crude oxo product is distilled under vacuum to remove unreacted olefins and paraffins. The bottoms are then further distilled under vacuum to separate the aldehydes and alcohols from the catalyst complex and the heavy ends. The aldehydes and alcohols fraction are then sent to the hydrogenation section; while about 90% of the heavy ends and catalyst bottoms are recycled directly to the oxo reactor. Thus in this commercial process the catalyst complex is subjected to two high temperature vacuum distillations. This lengthy contact time at relatively high temperatures augments the possibility of some catalyst complex decomposition which results in decreased catalyst life and increased costs. In the present process, the catalyst complex experiences a once-through distillation for a relatively short contact time at lower temperatures and thereby reduces catalyst decomposition. This reduction in catalyst decomposition affords the inherent advantage of extended catalyst life. As shown in the illustrative examples below, the catalyst recovered by this process also results in improved selectivity to alcohols with extended use of the recycled catalyst. 
     A comparison of distillation time, and bottoms temperature vs. catalyst decomposition is given below: 
     
         ______________________________________                                    
                  Commercial Conventional                                 
          Thin Film                                                       
                  Process    Vacuum Dist.                                 
______________________________________                                    
Distillation                                                              
Technique                                                                 
Catalyst Complex                                                          
Exposure Time to                                                          
Heated Surface                                                            
Bottom Tempera-                                                           
            &lt;1 minute About 2 hours                                       
                                 5-10 hrs                                 
ture, ° F                                                          
            200-250   About 1 hr 200-450                                  
                      at 370° F                                    
                      About 1 hr                                          
                      at 428° F                                    
Condition of                                                              
            Very little                                                   
                      Some cata- Essentially                              
Catalyst    decomposi-                                                    
                      lyst decompo-                                       
                                 complete                                 
after Distillation                                                        
            tion      sition     catalyst                                 
            Catalyst  Necessary to                                        
                                 decomposition                            
            could be  regenerate                                          
            recycled  part of                                             
                      catalyst                                            
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     The invention is illustrated by the following examples: 
     EXAMPLE I 
     Cobalt stearate (51.4 g., 0.06 mols of cobalt), tri-n-butylphosphine (12.6 g., 0.06 mols) and the C 11  -C 14   alpha olefins from wax cracking (345.6 g., 2.0 mols) were added to a 1000 ml stainless steel autoclave and the reactor was flushed with synthesis gas (hydrogen:carbon monoxide molar ratio of 2), pressured to 700 psig and heated to reaction temperature (340° F). Once the reaction temperature was reached, the reactor was pressured with the synthesis gas (hydrogen:carbon monoxide molar ratio of 2) to 1300 psig. The reaction was allowed to continue until no further uptake of the synthesis gas was observed. At the end of this time (90 minutes), the autoclave was cooled, vented and emptied. The crude reaction mixture was then thin film distilled at 200° F., maximum vacuum and an average charge rate of 60 ml/hour to separate unreacted olefins, mixed paraffins, aldehydes and/or alcohols from the catalyst complex and heavy ends. The overhead distillate was then vacuum fractionated to remove unreacted olefins and mixed paraffins. Next the product alcohols were taken overhead in 57 mol % selectivity while olefin conversion was calculated as 93 wt. %. Ninety weight percent of the catalyst complex and heavy ends was recycled as catalyst for the next reaction (Example 2). 
     EXAMPLE II 
     The C 11  -C 14  alpha olefins from wax-cracking (345.6., 2.0 mols) and the catalyst complex and heavy ends from Example I (84.2 g., 90% of thin film distillation residue recovered from Example I) were added to a 1000 ml stainless steel autoclave and the reactor was flushed with synthesis gas (hydrogen:carbon monoxide molar ratio of 2), pressured to 700 psig and heated to reaction temperature (340° F). Once reaction temperature was reached, the reactor was pressured with the synthesis gas (hydrogen: carbon monoxide in a molar ratio of 2) to 1300 psig. The reaction was allowed to continue until no further up-take of the synthesis gas was observed. At the end of this time (90  minutes), the autoclave was cooled, vented and emptied. The crude reaction mixture was then thin film distilled at 200° F. under maximum vacuum and at an average charge rate of 60 ml/hour to separate unreacted olefins, mixed paraffins, aldehydes and/or alcohols from the catalyst complex and heavy ends. The overhead distillate was then vacuum fractionated to remove the unreacted olefins and the mixed paraffins. The product alcohols were then taken overhead in 73 mol % selectivity. Olefin conversion was calculated as 99 wt. % . Ninety weight percent of the catalyst complex and heavy ends was recycled as catalyst along with fresh makeup catalyst for the next reaction (Example III). 
     EXAMPLE III 
     The C 11  -C 14  alpha olefins from wax cracking (345.6., 2.0 mols), catalyst and heavy ends from Example II (72.0g., 90% of thin film distillation residue recovered from Example II), and cobalt stearate and tri-n-butylphosphine (5.0 g., and 2.5 g., respectively, added as fresh &#34;make-up&#34;  catalyst) were added to a 1000 ml stainless steel autoclave and the reactor was flushed with synthesis gas (hydrogen: carbon monoxide molar ratio of 2), pressured to 700 psig and heated to reaction temperature (340° F). Once reaction temperature was reached, the reactor was pressured with the synthesis gas (hydrogen:carbon monoxide in a molar ratio of 2) to 1300 psig. The reaction was allowed to continue until no further uptake of the synthesis gas was observed. At the end of this time (90 minutes), the autoclave was cooled, vented and emptied. The crude reaction mixture was then thin film distilled at 200° F., maximum vacuum and an average charge rate of 60 ml/hr to separate unreacted olefins, mixed paraffins, aldehydes and/or alcohols from the catalyst complex and heavy ends. The product alcohols were taken overhead in 87 mol. % selectivity. Olefin conversion was calculated as 94 wt. % 
     Since catalyst decomposition is held to a minimum by use of the thin film separation, the present invention allows for direct recycle of the catalyst bottoms to the oxo reactor. Direct recycle of the catalyst bottoms eliminates costly catalyst recovery and the regeneration step generally required when conventional vacuum distillation conditions are employed.