Process for making a mixture of ethylene and butene-1
BACKGROUND OF THE INVENTION 
     This invention relates to a process for the preparation of a mixture of ethylene and butene-1. 
     It is known from U.S. Pat. No. 4,133,944, dated 1-9-79 (Col. 5 and 6) that ethylene copolymers can be prepared using a mixture of ethylene and butene-1 wherein the mixture is prepared in the polymerization reactor or in a separate dimerization stage before the polymerization reactor. 
     The selective dimerization of ethylene to butene-1 is known from U.S. Pat. No. 4,245,131 dated 1-13-81. The production of a mixture of ethylene, and higher alpha olefins using a coil reactor is disclosed in U.S. Pat. No. 3,721,719, dated 3-20-73. However, the instant process is selective for the production of butene-1 and gives a higher butene-1 to trialkyl aluminum ratio, i.e., more weight of product per unit weight of catalyst. 
     SUMMARY OF THE INVENTION 
     This invention relates to a process for making a mixture comprising ethylene and butene-1 wherein ethylene is reacted with an excess of a dilute trialkyl aluminum solution in a solvent therefore under a pressure in the range from 100 to 1500 psig and preferably 300 to 600 psig, a temperature in the range from 200° to 325° C. and preferably 250° to 280° C., an ethylene to trialkyl aluminum weight ratio in the range from 200:1 to 20,000:1 and preferably 4000:1 to 8000:1. The reaction is conducted in a vertical reaction zone with the contact between the ethylene and the trialkyl aluminum solution taking place at the lower end of the reaction zone. This reaction raises the temperature of the reactants to the boiling point of the solvent whereby the reactants vaporize and are condensed in the cooler upper end of the reaction zone. The solvents used are inert solvents such as alkanes or alkenes having 8 to 40 carbon atoms. 
     This reaction zone is called a boiling bed reaction zone for the purposes of this invention. 
    
    
     DESCRIPTION OF THE DRAWING 
     The drawing is a schematic description illustrating how the invention is carried out. 
    
    
     In the drawing, the ethylene gas inlet 10 flows into a preheater 12 and then into the vertical reactor 14. A gaseous diffuser or sparger 16 is provided to disperse or break up the ethylene gas for better contact. The level of the dilute solution of trialkyl aluminum in a hydrocarbon solvent is shown at 18. This level is maintained by the liquid controller 37 and its associated control valve 38. 
     If it is needed or desired a conventional heating device 15 is provided which can be an electric heating tape, fluid heating coils, or a reboiler. 
     In the upper end of the vertical reactor 14 there is provided a conventional contact device such as mesh packing, ceramic rings and other known contact devices. 
     The mixture of ethylene and butene-1 leaves the reactor 14 by line 22 where it is cooled by heat exchanger 24. 
     A reflux drum 26 provides for the condensation of solvent vapor and the liquid is returned to the reactor 14 by line 28. 
     The pressure in the reactor 14 is maintained within predetermined limits by the pressure controller 31 which regulates control valve 32. 
     The mixture of ethylene and butene-1 flows from the drum 26 through the control valve 32 into the outlet line 34. 
     DETAILED DESCRIPTION OF THE INVENTION 
     The following detailed examples are given for the purpose of further illustrating the invention. 
     EXAMPLE 1 (DB 29359-5) 
     High purity (99.9%) ethylene at 400 psig was sparged at 1.5 liters per minute (0.32 cm/sec.) through a stainless steel frit at the bottom of a 1 inch O.D. stainless steel pipe 54 inches long. A prepared solution of 0.4 wt. % triethylaluminum (TEA) in n-tetradecane was added to the reactor such that the liquid height was maintained at 2.7 inches. The liquid was recycled through a feed reservoir at a rate of 4 cc per minute. The liquid/gas mixture was heated to 277° C. by means of a variac controlled heating tape and reflux was provided by 3 inches of mesh packing in the top of the reactor. Overhead gases were passed through a wet test meter and vented. Analysis of the vent gases and TEA/solvent recycle were performed by gas chromatography. TEA catalyst concentration was based on measuring the ethane liberated by careful hydrolysis of solvent aliquots. After 300 minutes run time, a total of 120.2 g. of ethylene had been converted (25.7 wt. %) yielding 100.5 g. of forward flow C 4  -C 8  oligomers. The product distribution in Table I was obtained: 
     
                       TABLE I                                                     
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                                 Reaction                                 
Forward Flow Product                                                      
               Wt. (g)  Wt. %    Selectivity %                            
______________________________________                                    
Ethylene       346.0    77.5                                              
Butene-1       95.8     21.5     95.5%                                    
Butene-2       1.5      0.35     1.5%                                     
Hexene-1       1.9      0.4      1.9%                                     
Hexene-2 &amp; Hexene-3                                                       
               0.23     0.05     0.2%                                     
2-Ethyl-1-Butene                                                          
               0.95     0.1      0.9%                                     
Octene-1       0.08     0.01     0.08%                                    
2-Ethyl-1-Hexene                                                          
               0.07     0.01     0.07%                                    
Total          446.53   99.92    100.15                                   
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     The unit ratio for the grams butene-1 produced per gram TEA added was 159. A total of 19.7 g. (16.4%) of the converted product was lost to solvent. 
     EXAMPLES 2-15 
     Following the procedure outlined in Example 1, the results outlined in Table II and III were obtained: 
     
                                           TABLE II                                
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            Gas  Gas       TEA C.sub.2 H.sub.4                            
                                    Wt..sup.(2)                           
Ex.                                                                       
   Temp.                                                                  
       Press.                                                             
            Res..sup.(1)                                                  
                 Velocity                                                 
                       Sol-                                               
                           Conc.                                          
                               Conv.                                      
                                    Prod.                                 
No.                                                                       
   (°C.)                                                           
       (psig)                                                             
            (sec)                                                         
                 (cm/sec)                                                 
                       vent                                               
                           Wt. %                                          
                               (g.) (g.)                                  
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2  261 400  47   0.36  C.sub.14                                           
                           0.11                                           
                               72.3  236.1                                
3  266 400  49   0.34  C.sub.14                                           
                           0.11                                           
                               135.6                                      
                                     458.4                                
4  273 400  77   0.31  C.sub.14                                           
                           0.28.sup.(3)                                   
                               194.5                                      
                                     375.9                                
5  266 400  148  0.25  C.sub.14                                           
                           0.10                                           
                               218.2                                      
                                     241.7                                
6  273 400  61   0.27  C.sub.14                                           
                           0.25                                           
                               172.4                                      
                                     335.7                                
7  268 405  38.6 0.54  C.sub.14                                           
                           0.29.sup.(3)                                   
                               428.6                                      
                                    1307.4                                
8  255 400  37   1.4   C.sub.14                                           
                           0.27                                           
                               1187.2                                     
                                    3039.7                                
9  260 410  39   1.32  C.sub.14                                           
                           0.10                                           
                               170  2355.8                                
10 250 400  60.6 0.78  C.sub.10 --1                                       
                           0.13                                           
                               821.3                                      
                                    4046.3                                
11 250 400  59   0.82  C.sub.10                                           
                           0.12                                           
                               265.6                                      
                                    1667.6                                
12 247 400  62.7 0.77  C.sub.10                                           
                           0.2 614.3                                      
                                    4720.6                                
13 248 410  46   1.15  C.sub.10                                           
                           0.23                                           
                               492.9                                      
                                    2889.0                                
Con-                                                                      
   257 330  229  0.18  C.sub.14                                           
                           0.25                                           
                               156.3                                      
                                     70.6                                 
trol                                                                      
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 .sup.(1) = residence time.                                               
 .sup.(2) = weight of product: total wt. of effluent gases during entire  
 run.                                                                     
 .sup.(3) = tri nbutyl aluminum replaced the TEA.                         
 C.sub.14 = ntetradecane.                                                 
 C.sub.10 --1 = decene1.                                                  
 C.sub.10 = ndecane.                                                      
 
    
     
                       TABLE III                                                   
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                                 Bte-1/                                   
                                 TEA                                      
Ex.  PRODUCT COMPOSITION (Wt. %) Unit                                     
No.  C.sub.2 H.sub.4                                                      
            Bte-1  Hex-1 Oct-1 C.sub.10.sup.(1)                           
                                    BAO.sup.(2)                           
                                          IO.sup.(3)                      
                                               Ratio                      
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2    76.9   21.9   0.4   0.01    0  0.2   0.3  219                        
3    77.9   20.2   0.7   0.03    0  1.1   0.5  324                        
4    65.0   31.5   1.0   0.02    0  1.2   1.3  154                        
5    60.8   32.7   1.4   0.04    0  2.15  2.9  556                        
6    65.7   29.1   1.1   0.04    0  2.1   1.8  279                        
7    71.4   25.3   1.7   0.04    0  1.0   0.5  801                        
8    62.5   31.0   2.9   0.2     0  1.0   0.8  879                        
9    93.2   5.5    1.0   0.1   0.02 0.1   0.05 291                        
10   84.0   13.5   1.5   0.04  0.23.sup.4                                 
                                    0.2   0.09 1099                       
11   84.5   13.2   1.3   0.06  0.2.sup.4                                  
                                    0.1   0.1  1554                       
12   87.2   10.8   1.3   0.09  0.2.sup.4                                  
                                    0.2   0.05 500                        
13   82.3   13.8   2.0   0.15  0.3.sup.4                                  
                                    0.03  0.09 1050                       
Con- 60.7   28.5   0.7   0.16    0  2.3   6.7   67                        
trol                                                                      
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 Foot Notes:                                                              
 .sup.(1) C.sub.10.sup.+  = hydrocarbons (especially olefins) having ten o
 more carbons.                                                            
 .sup.(2) BAO = branched alpha olefins, e.g., 2ethyl-1-butene.            
 .sup.(3) IO = internal olefins, e.g., butene2.                           
 .sup.(4) This C.sub.10.sup.+  material is solvent ndecane which is not   
 refluxed back down the reactor.                                          
 Bte1 = butene1.                                                          
 Hex1 = hexene1.                                                          
 Oct1 = octene1.