FOR DIRECT FLUORINATION OF A

HYDROCARBON BY MOLECULAR FLUORIHE GAS

FIELD OF THE INVENTION

The present invention relates to a method and apparatus for direct fluorination of hydrocarbons (1 to 4 carbons) by using molecular fluorine gas in a liquid medium. The number of reactors or reaction steps is a function of the number of hydrogen atoms in the hydrocarbon to be replaced by molecular fluorine to produce a refrigerant.

BACKGROUND OF THE INVENTION This invention deals with a method and apparatus to produce HCF's and CF's non-restricted with the potential of being substitutes for the restricted refrigerants used at the present time. The prior art teaches some methods used in the preparation of fluorocarbons and hydrofluorocarbons and, in general, the preparation of chlorofluorocarbons and chlorohydrofluorocarbons. However, the presence of by¬ products is one of the main considerations in the selection of the method and apparatuβ for the manufacturing process. See John D. Calfee and Lucius A. Bigelow, J. Am. Chem. Soc. 59 (1937) 2072 disclosed in the series of papers, "The Action of Elemental Fluorine on Organic Compounds," IV The Vapor Phase Fluorination of Ethane. It discloses hydrogen substitution by fluorine, as well as chlorine substitution by fluorine. The apparatuβ described is considered today a typical vapor phase reactor for the fluorination of organic compounds.

In a continuation of the series "The Action of Elementary Fluorine Upon Organic Compounds," Eduard A. Tyczkowski and Lucius A. Bigelow introduce the jet fluorination reactor. The jet, venturi or adductor reactor used in the prior art, is a combustion chamber in which the

hydrocarbon acts as the fuel and the fluorine as the oxidizer. A mixture of several fluorinated products is obtained when jet vapor fluorination is conducted. Recently, jet fluorination was proposed in a liquid phase, but apparently, several problems arose in the suction portion of the venturi where the reaction takes place. Apparently, because fluorine is highly reactive, it was difficult to control the reaction, which resulted in inconsistent products and malfunction of the apparatus. Accordingly, it is an object of the present invention to provide fluorinated hydrocarbons by using an apparatus and method in which the reaction is controllable and the desired fluorinated product is obtainable without product deterioration and without undesired by-products. It is another object of the invention to provide a method and apparatus for the fluorination of hydrocarbons for replacement of the restricted halocarbons, such as freon, that cause ozone depletion.

It is another object of this invention to provide the method and apparatus for the purification of the fluorinated hydrocarbons.

It is another object of the invention to provide a contacting zone or reaction vessel where the interactive effect takes place in the area of contact of the two reactants, fluorine and hydrocarbon. The two reactants contact and react with each other in a medium of liquid solvent, which acts as a heat sink to prevent the overheating effect of the high rate of the reaction.

It is another object of the invention to provide a tubular reactor with a laminar flow of solution fluid to prevent any back mixing of the fluid. The laminar flow without the back mixing prevents undesired by-product formation.

It is another object of the invention to provide a fluorination reactor with one or more fluorine feeder injectors to produce fluorinated compounds from one fluorine in the molecules to perfluorinated molecules. It is another object of the invention to provide a separation stage for the removal of dry hydrogen fluoride as a secondary product. The dry hydrogen fluoride is a source of raw material in fluorine electrolysis and can be reused. It is another object to provide a closed system which produces the desired final product, with a minimum of by¬ product produced, and wherein the solvent is reused, and the hydrogen fluoride by-product may be reused in fluorine electrolysis.

SUMMARY OF THE INVENTION The present invention provides a method and apparatus for the direct fluorination of organic compounds, and more specifically, the fluorination of hydrocarbons within (1 to 4 carbons) a liquid medium. The apparatus includes at least three vessels: the interacter vessel, the thermobath vessel, the gas vessel, and the solubilizer vessels. One solubilizer vessel is used to dissolve or blend the fluorine with the fluorinated solvent, and the other solubilizer vessel is used to dissolve the hydrocarbon to be fluorinated with the fluorinated solvent. Each interacter vessel has at least two connections to feed the fluorine solution and the hydrocarbon solution. The number of interacter vessels and the number of solubilizer vessels for fluorine solution are increased to replace additional hydrogen atoms by fluorine in the hydrocarbon. In its broad aspect, the method and apparatus of the present invention provides fluorination and purification of hydrocarbons by mixing molecular fluorine with fluorinated liquid solvent in a solubilizer fluorine vessel, mixing hydrocarbon with fluorinated liquid solvent in a solubilizer

hydrocarbon vessel, injecting these into an interacter fluorination reactor, where the solution of fluorine liquid solvent contacts the solution of hydrocarbon liquid solvent, and the two solutions interact together and the reaction is initiated. The fluorinated liquid solvent is inert to fluorine under the process condition of temperature and fluorine concentration. The operating temperature is, in general, around the boiling point of the fluorinated liquid medium. BRIEF DESCRIPTION OF THE DRAWINGS

Further objects, features, and advantages of the present invention will become apparent upon consideration of the detailed description of the presently-preferred embodiment, when taken in conjunction with the accompanying drawings wherein:

Figure 1 is a schematic diagram of the apparatus of the present invention;

Figure 2 shows the vessels interconnected; Figure 3 shows the present invention in a two-stage arrangement, wherein there is a second stage to replace a second hydrogen atom in the hydrocarbon with fluorine;

Figure 4 shows an eight-stage arrangement, wherein eight hydrogen atoms are replaced with fluorine in accordance with the present invention; Figures 5A, 5B, and 5C show alternative arrangements of the interacter or mixer vessel;

Figures 6A and 6B show the solubilizer vessels for the fluorine and hydrocarbon;

Figure 7 shows the thermobath unit; and Figure 8 shows the condenser.

DESCRIPTION OF THE PREFERRED EMBODIMENT The presence of chlorine, bromine, or iodine in halocarbons implies a severe restriction on handling imposed by the Environmental Protection Agency in regards to

atmospheric damage when they are disposed of. The era of using these compounds as refrigerants or chemical intermediaries ended with the Montreal protocol. In the present invention, the refrigerant replacement is free of chlorine, bromine, or iodine, and the reactants are free of chlorine, bromine, or iodine. According to the present invention, hydrocarbons (1 to 4 carbons) are fluorinated by direct fluorination with molecular fluorine that only contain carbon, hydrogen, and fluorine or carbon and fluorine. The principal group of hydrocarbons used in this invention for the preparation of refrigerants are methane, (CH ), ethane (C ₂ H ₆ ) propane (C ₃ H ₈ ) and butane (C ₄ H ₁₀ ). By using the method and apparatus of this invention, some of the final products produced are: R-23 Fluoroform CHF ₃

R-152 Difluoroethane C ₂ H F ₂

R-143 Trifluoroethane C H ₃ F ₃ R-134 Tetrafluoroethane C ₂ H ₂ F ₄ R-125 Pentafluoroethane C ₂ HF ₅ R-227 Heptafluoropropane C ₃ HF ₇

R-116 Hexafluoroethane ^C ₂ ^F ₆ R-218 Perfluoropropane ^c ₃ ^F β The method and apparatus of the invention is to produce perfluoroethane, perfluoropropane, perfluorobutane, and hydrofluorocarbons. The fluorination reactor 10 consists of a tubular reactor with multifeed points for fluorine solution and a single feed for the hydrocarbon, such as ethane, propane, or butane solution. The reactor has as many cooling zones as the fluorine solution feeds. Each fluorine solution feed corresponds to a predetermined concentration and is prepared in its own fluorine solvent mixer. The fluorination apparatus has as many fluorine solvent mixers as fluorine solution feeders in the reactor. The fluorine solution mixer consists of a tank with a cooling medium for removing the

heat of solution of fluorine in contact with the fluorinated solvent. The fluorine is preferably injected into the bottom portion of the tank, as well as the fluorinated solvent. The fluorine solution travels along the fluorine solution mixer, and cooling is provided by a cooling medium. The fluorine solution mixture is withdrawn from the fluorine solution mixer from a connection opposite to the fluorine injection. Figure 1 is an illustration of a mixer 40 of the invention apparatuβ. One of the fluorinated solvents used in the invention illustration is perfluoropropane. The fluorine solvent mixer 40 has an injection port for fluorine and an injection port for perfluoropropane (solvent).

Equipment and Components The apparatus in Figure 1 illustrateβ a process plant, which consiβtβ of an interacter 10, a thermobath tubular reactor 20, a fluorine solubilizer 40, a hydrocarbon solubilizer 50, a condenser 30, a hydrogen fluoride separator 60, a product extractor 70, a product receiver 80, a solvent receiver 90, a solvent recycle pump 110, a compressor for gas recycle 120, and a hydrogen fluoride pump 100. The solvent recycle pump 110 discharges the fluid to the solvent feeder 205 and solvent feeder 206 for reuse. The fluorine feed 24 in solubilizer 40 is disβolved with βolvent supplied 205. Fluorine iβ dissolved in the solution in the solubilizer 40. The hydrocarbon supplied to solubilizer 50 is disβolved with the solvent supplied by 206. The hydrocarbon is dissolved in the solution in the solubilizer 50. The fluorine solution feeder 201 and the hydrocarbon solution feeder 203 operate at the same discharge pressure. The fluids from feeder 201 and from feeder 203 interact in the interacter 10, where the main portion of the reaction takes place. The velocity of the combined flows from 201 and from 203 iβ sufficiently fast that the heat dissipation takes place in the body of the solution in the thermobath 20. In the bottom portion of the

interacter 10 is the recycle feeder 202, which assists the fast displacement of the βolution to the thermobath 20.

The solubilizer 40 is cooled by a cooling medium 48, so that the temperature is maintained lower than the minimum temperature of reaction between fluorine and the solvent. The solubilizer 50 is cooled by a cooling medium 58, so the temperature is maintained lower than the minimum temperature of reaction between fluorine and the solvent. The cooling medium may be a coil of C0 ₂ liquid, glycol water, or a refrigerant system. The diameter of reactor 10 is sufficiently large to maintain laminar flow along the reactor from the bottom to the liquid discharge 204. Any residual unreacted gas, hydrocarbon, fluorohydrocarbon, or fluorine saturated with solvent flows to the condenser 30 where the solvent is condensed and the non-condensable parts are accumulated in the gas portion of the condenser 30. The unreacted vapor from the top of the condenser 30 is recycled by compressor 120 to the interacter 10 via line 202. The condenser 30 has a cooling medium 38 for the cooling and condensation of any vapor condensable at the operating temperature.

The liquid solution 204 discharged through 204 is fed into a separator 60 where the hydrogen fluoride is extracted and discharged through line 211 by the pump 100. The βolution free of hydrogen fluoride is transferred to separator 70, from the top of separator 60, by using the line 208. In the separator 70, the purified product is extracted at the top by using line 210 and is supplied to product collector 80, and at the bottom of 70, the solvent is transferred to solvent receiver 90 through line 211. The solvent in receiver 90 is recycled back to the solubilizers 40 and 50 by using line 205, 206, 207, and pump 110. The separator 70 has at least one cooling medium 78 and at least one heater 88. The separator 60 has at least one heater 98

and at leaβt one cooling medium 68. The βeparator 60 and separator 70 are standard distillation equipment and are considered as part of standard engineering practice but are essential in this method and apparatuβ invention. Figures 3 to 6 are illuβtrationβ of the typical apparatuβ of the invention for the fluorination of hydrocarbons. Figures 5A, 5B, and 5C illustrate different forms of the interacter 10, which, in this case, iβ a "T" with injector feeders. The selection of a "T" is for simplicity, but other geometrical shapes may be used. The embodiments shown in Figures 5A, 5B, and 5C each have at least two feeder ports 12 and 14, one for the fluorine solution and the other for the hydrocarbon solution, and one discharge port 16. The feeder ports normally have an injector 18 to increase the velocity for the dynamic interaction. The discharge port 16 of the "T" iβ the outlet or connection to the thermobath 20 where the fluid iβ changed to a laminar flow.

Figureβ 6A and 6B show solubilizerβ 40 and 50, which are "T"-βhaped with injector feederβ 42 and 52 for the βolvent and injectorβ 44 and 54 for fluorine and for hydrocarbon. The solubilizer 40 has a cooling medium 48, and the solubilizer 50 has a cooling medium 58 to maintain the temperature at the desired condition. Figure 8 is an illustration of the gas condenser 30, where one branch 204 is the discharge to the βeparator, and the other branch 120 is the gas recycle port. Three of the four main components of the apparatus invention in illustrationβ Figure 5, 6, and 8 are "T'^type unite. The "T" type of βolubilizer and the "T" type of interacter 10 characterize the apparatus for the fluorination of hydrocarbons in a liquid solvent medium.

Figure 7 is an illustration of the thermobath unit 20 used as part of the "T" fluorination apparatus of Figure 2.

The thermobath is a pipe 20 with a cooling medium 28, sufficiently large in diameter that the fluid is in laminar flow. Any heat from the reaction mainly produced in the corresponding interacter 10 is removed by the cooling medium 28 of the thermobath 20. The dynamic interaction of the ingredients in the interacter 10 produce a uniform solution at the entering point 22 of the thermobath 20, and the uniformity of the overall composition will not mitigate from one point of the thermobath to another point, because the fluid is in laminar flow.

Figures 2 to 4 illustrate three types of arrangements of the "T" apparatus. Figure 2 is for a single-stage vertical arrangement. Figure 3 is for a two-stage horizonal arrangement, and Figure 4 is for a multistage vertical arrangement. Figure 2 illustrateβ a vertical arrangement with a single βection and one-βtep fluorination. Figure 3 illuβtrateβ two βteps of fluorination. Figure 4 illustrates multisteps of fluorination.

Figure 2 shows the solubilizers 40 and 50 connected to reactor 10, thermobath 20, and condenser 30. In solubilizer or vesβel 40, molecular fluorine gaβ is dissolved in liquid βolvent to produce a firβt liquid or solution. In solubilizer 50, the hydrocarbon to be fluorinated is dissolved in a liquid solvent to produce a second liquid or solution. Reactor 10 has a first injector 10a for injecting the first liquid into it with a turbulent flow and a second injector 10b for injecting the second liquid into it with a turbulent flow, so that the first and second liquids are uniformly mixed in reactor 10 and reacted with each other to produce a reaction liquid, which is supplied to thermobath 20 by injector 10c. Thermobath 20 includes cooling medium 28 for cooling the heat of the reaction in the reaction liquid, and it produces laminar flow (as opposed to turbulent flow) of the reaction liquid through the thermobath vesβel to

complete the reaction. Injectorβ 10a and 10b are diβposed at 90° relative to each other to increaβe the turbulent flow in reactor 10 to enhance the mixing and reaction of the first and βecond liquids. Condenser 30 is connected to thermobath 20 to condense any vapor, and it may include a cooling medium. Its output at 204 is supplied to separator 60. Separator 60 receives the reaction liquid and separates the HF by-product therefrom to produce the final product and solvent, which is then supplied to βeparator 70 for separating the final product from the liquid solvent. The final product is collected in collector 80, and the solvent is supplied to unit 90 for reuse and reβupply to βolubilizerβ 40 and 50 to provide a continuous closed βyβtem for producing the final product. Similarly, the output of condenβer 30 iβ fed back and recycled to reactor 10 for reuβe. Typically, the output of condenser 30 is gas and the unreacted fluorine and hydrocarbon. The various vesβels 10, 20, 30, 40, and 50 may be stainleβs steel, brasβ, copper, monel, or other suitable materials. In the preferred embodiments, the solvents may be perfluoropropane or perfluorobutane, and the hydrocarbon may be methane, ethane, propane, or butane.

Figure 3 shows two stageβ, with an additional reactor 10', an additional fluorine βolubilizer 40', an additional thermobath 20', and an additional condenβer 30'. In thiβ second stage, a second hydrogen atom in the hydrocarbon C _N H _N+2 is replaced by molecular fluorine to produce the final product.

To illustrate the ranges for the process parameters of the invention, one product will be used as an example.

Figure 4 is an illustration of the method and apparatus for the fluorination of propane into perfluoropropane. The apparatuβ consists of eight fluorination steps, as shown, and in each step of the "T" apparatus, there iβ βubstituted one

hydrogen of the propane molecule with fluorine. In eight steps, eight hydrogens are replaced by eight fluorines, and the propane molecule is transformed into perfluoropropane.

Each stage consists of an interacter zone 10 with a (propane/fluorinated propane-perfluoropropane) βolution feeder, a (fluorine-perfluoropropane) solution feeder, and reacted solution is discharged to the thermobath zone 20. The fluorine solution of fluorine and perfluoropropane (the solvent) is prepared in the fluorine solubilizer 40 where the perfluoropropane is injected through a solvent feeder 205, and the fluorine is injected through a solute feeder 24. The fluorine as βolute iβ dissolved in the body of perfluoropropane. The range of temperature in the fluorine solubilizer 40 is from about (-40°C to +40°C) and the range of presβure from about (20 pβia to 200 psia). The temperature range and the preββure range in the interacter 10 for the preparation of perfluoropropane are the βame in all the componentβ. Temperature in the range of (-40°C to +40°C) and presβure in the range of (20 psia to 200 pβia). The propane solubilizer 50 has the perfluoropropane feeder 206 for supplying perfluoropropane to the solubilizer 50. The flow at feeder discharge 203 iβ in a turbulent flow condition, with the Reynoldβ number in the range of about from 5,000 to about 500,000. The propane iβ fed via 220 in a turbulent flow condition, βimilar to the perfluoropropane. The fluorine solubilizers have the βame design criteria as the propane solubilizer.

The interacters 10 are designed with the condition of turbulent flow, including rotational motion of the fluids. The interaction in interacters 10 between the fluids from the two feeders 40 and 50 is total. The two feeders are at 90° with respect to each other. This design condition provides rotational motion, which induceβ better contact of the two fluid streamβ and more interaction between the reactants.

The thermobath 20 is designed with the condition of laminar flow to prevent back migration of the reactants and to provide enough retention time for temperature equilibrium. The Reynolds number for the thermobath zone iβ in the range from 15 to 1,500.

Example An apparatus with the capacity to process 1 mole/hour of propane, uses a propane solubilizer 50 with perfluoropropane injection feed of about 836 lbs/hour, which produces a βolution of 5% by weight of propane in perfluoropropane. The fluorine βolubilizers 40 of each stage require an injection feed of fluorine of 1 mole/hour and perfluoropropane feed of 342 lbs/hour to produce a solution of 10% by weight of fluorine in perfluoropropane solution. Each interacter 10 of the apparatus places in contact 1 mole/hour of fluorine with 1 mole/hour of propane and generates 1 mole/hour of hydrogen fluoride. At the top of the apparatuβ, the amount of perfluoropropane increases by 5%. The 5% increment is the product generated in the apparatus. At the top of the apparatus, 8 moles/hour of hydrogen fluoride are in the solution. The rate of perfluoropropane production iβ 1 mole/hour or 188 lbs/hour. The perfluoropropane inventory in the apparatus is about 3,600 lbs.

The new method and apparatus of the present invention for the fluorination of hydrocarbons have the following advantages and benefits: the preparation of several fluorinated compounds in the same apparatus; a minimum amount of by-product iβ generated; a continuouβ operation without any difficulty; a variable capacity or rate of production, as desired; easy recovery of hydrogen fluoride with high quality for the application; and a recyclable product that meets the desired specifications.

The present invention has applications for producing refrigerants and for producing degreaβing agents used for

cleaning oily surfaces, and for producing plaβma for uβe in the field of βemiconductors.

A latitude of modification, change, and substitution iβ intended in the foregoing disclosure, and in some instances, βome features of the invention will be employed without a corresponding use of other features. Accordingly, it iβ appropriate that the appended claims be conβtrued broadly and in a manner consistent with the spirit and scope of the invention herein.