In particular, the present invention seeks to provide improved acid-catalysed reactions of alcohols (whether aliphatic, aromatic or heterocyclic) to produce ethers, alkenes, acetals or ketals as required.

The use of acid catalysis in industry is widespread and of importance.

We have shown that reactions of industrial importance such as ether, acetal, ketal and alkene formation can be carried out under supercritical or near critical conditions of temperature and pressure using a heterogeneous acid catalyst with significant advantages. Their use in supercritical fluids has not previously been described.

Using supercritical fluids as a solvent eliminates the need for conventional organic solvents and hence gives environmental benefits. However, a more important consequence is that the reactions can be modified by using supercritical fluids to give surprisingly high yields and/or selectivities.

We have also found that certain products which are not easily accessible by conventional routes can be obtained more easily using the process of the present invention. Thus, whilst rearrangements may occur in conventional reactions we have found that certain reactions can be carried out under the conditions of

the present invention without any significant rearrangement occurring. For example, ether formation in supercritical fluids under the conditions of the present invention can give rise to enhanced yields of n-alkyl ethers rather than the branched products which are obtained in conventional procedures.

Ethers Conventionally, the formation of ethers can be carried out via a wide number of classical routes e. g.

Williamson Synthesis, dehydration of alcohols, alkylation of alcohols with inorganic esters, and alkylation with diazo compounds.

In the Williamson synthesis an alkyl halide is reacted with an alkoxide or aryloxide. This reaction therefore involves preforming the alkoxide from an alcohol by reaction with a strong base and subsequent reaction with an alkyl halide. This results in the generation of an equimolar amount of a halide salt which then must be disposed of. There are also the hazards associated with the handling of the alkyl halide in the case of volatile and/or toxic halides such as methyl iodide which is both a known carcinogen and very volatile.

In the case of reactions of alcohols with inorganic esters (e. g. the reaction of an alcohol with dimethyl sulfate), the inorganic esters are usually highly toxic. Again the alcohol has to be converted to the alkoxide using a strong base prior to the reaction.

A further problem is the disposal of the aqueous effluent which can contain large amounts of inorganic salts.

The reaction of diazo compounds with alcohols is a cleaner reaction but suffers from the dangers

associated with the thermal decomposition of diazo compounds. Also, diazo compounds are expensive and so it is not practicable to carry out this reaction on an industrial scale except for very high value products.

One of the most cost-effective and atom-efficient processes for producing ethers is the dehydration of alcohols using an acid catalyst. This reaction is usually carried out in the liquid phase but suffers the drawback that, in the reaction of n-alcohols, the alcohol can rearrange from the primary to secondary and then to the tertiary carbocation, thereby giving a mixture of products. A further problem is that the use of homogeneous catalysts such as sulphuric acid require a separation or neutralisation step at the end of the process. The use of homogeneous catalysts means that these processes are usually carried out in batch or semi-batch reactors. The use of batch systems also gives increased down time for charging and discharging.

There is also the disadvantage that the product will be a mixture of thermodynamic and kinetic products due to relatively long residence times in the reactor.

Distillation or some other physical means of separation is therefore usually required to separate the products.

A number of other reactions are also carried out to form ethers, usually on a smaller scale, such as the reaction of a Grignard reagent with an acetal or cyclisation of alcohols with lead, silver or mercury salts all of which suffer from high cost and problems of waste disposal.

Acetals and Ketals The most widely used method of formation of acetals and ketals is the reaction of alcohols with aldehydes or ketones under acidic conditions which

involves the removal of water. These reactions are usually carried out in an excess of the alcohol or in an inert solvent. The conventional process therefore presents the problem of removing excess reagent and the catalyst must also be separated from the mixture if a homogenous catalyst is used.

Alkenes The industrial preparation of alkenes is normally carried out by dehydrogenation over noble metal catalysts or cracking reactions or dehydration reactions using inorganic acids. Such reactions present the problems of removal of catalyst, reaction solvent and distillation to purify products.

We have found that the use of supercritical fluids for the replacement of conventional solvents not only has significant environmental benefits but also leads to cleaner, higher yielding reactions.

Although the mechanism of the reactions is not fully understood it is believed that mass transport effects play a role in the observed improvements in yield and/or product selectivity. Surprisingly, the use of a heterogeneous catalyst in place of a homogeneous catalyst under near-critical or supercritical reaction conditions does not render the reaction ineffective. Instead we have found that the reactions benefit from improved yields and/or selectivity in product formation. This is so despite the expectation that the relatively severe conditions at or near the supercritical point of the reaction medium may give rise to a mixture of products because the reactants have sufficient energy to react via several different pathways.

One consequence of using the heterogeneous catalyst is that there is no need for complicated separation procedures to liberate the product from the reaction mixture and catalyst. This represents quite a benefit in terms of both the time savings and cost savings of the present invention.

We have thus found that it is possible by using a combination of supercritical fluids and a heterogeneous catalyst (e. g. the Deloxan ASP catalyst from Degussa or Acidic Amberlyst resin from Rohm and Haas) in a _ continuous flow reactor to carry out a number of reactions rapidly and cleanly. These reactions can often be performed in high yield and take place under near-critical or supercritical conditions.

According to the present invention, there is provided a process in which an organic compound having the formula RlCH2OH, R1R2CHOH, or RlR2R3CoH is exposed, optionally in the presence of one or more further organic compounds having the formula R'CH2OH, R5R6CHOH, R7R8R9CoH or R10RllCO, to a heterogenous catalyst which is able to provide a source of acid in a continuous flow reactor under supercritical or near-critical conditions with the result that an ether, acetal, ketal or alkene product is formed, wherein the conditions of temperature, pressure, and flow rate are independently controlled, and wherein each of Rl to Rll is independently selected from: hydrogen, hydroxyl, or an optionally substituted alkyl, alkenyl, alkynyl, aralkyl, cycloalkyl, cycloalkenyl, aryl or heterocyclic group.

Aliphatic and aromatic alcohols are preferred because they give cleaner reactions, with aliphatic alcohols being most preferred on the grounds of ease of use and lower occurrence of side products.

It is preferred that each of R'to R"when present is an alkyl group which may be optionally substituted.

Since the process of the present invention is applicable to diols, triols and higher alcohols as well as alcohols, it is particularly preferred that the optional substituent, when present, on one of the groups RI to R"is hydroxyl. It is also preferable, in order to avoid the risk of unwanted side products, that the total number of alcohol groups within the organic compound does not exceed three.

When any of the R'to R"groups are optionally substituted, the substituent groups which are optionally present may be any conventional substituent provided that any such substituent is not incompatible with alcohol functionality or with the reaction conditions.

Generally, when any of the R1 to Rll groups represents an optionally substituted alkyl group each group may independently be linear or branched and suitably contain 1 to 10, preferably 1 to 6 carbon atoms in the carbon chain, not including any optional substituent which may be present.

In relation to alkyl groups, specific examples of such optional substituents include halogen atoms and nitro, hydroxyl, Cl4 alkyl, Cl4 haloalkyl (especially CF3), Cl4 alkoxy, Cl4 haloalkoxy and (Cl_4 alkoxy) carbonyl groups. Of these, hydroxyl and Cl4 haloalkyl are preferred. It is preferred, however, that when any of groups RI to R1l is alkyl that the alkyl moiety is unsubstituted.

In relation to a phenyl moiety, optional substituents include halogen atoms, and nitro, hydroxyl, Cl4 alkyl, Cl4 haloalkyl (especially CF3) and Cl4 alkoxy groups.

In general, 1 to 3 optional substituents may suitably be employed. Halogen atoms when present are preferably fluorine.

Where the starting materials for the reaction may exist in isomeric form the reaction of the present invention is applicable to all such optical or geometric isomers.

Suitable catalysts include Deloxan acid catalysts (Ex. Degussa-Huls AG), zeolites, metal oxides, molecular sieves, clays, sulfonic acid derivatives, or other equivalent heterogeneous sources of a Brnsted acid (e. g. Amberlyst resin). The catalyst is ideally supported on an inert carrier. Preferably the catalyst contains sulfonic acid groups, and more preferably the catalyst is a Deloxan catalyst or an equivalent thereof.

The reactions of the present invention are preferably carried out in a single homogeneous phase.

However, in reactions where water is generated this may separate out as a separate phase. This separation can be helpful to the reaction. Preferably, the reactions are performed in the supercritical phase.

In the context of the present invention, the lower limit suitable for supporting the reaction is a condition of temperature and pressure below or near to (perhaps at) the critical point of the solvent. When a fluid reaches its critical point its density is substantially decreased relative to its density at its boiling point at normal pressure. Small changes in pressure or temperature near the critical point cause additional changes in density. The process of the present invention will operate in the fluid at temperatures and pressures below the critical point but at which the density is sufficient to ensure solvation

of reagents.

The upper limit of temperature and pressure is governed only by limitations of the apparatus.

In practice, the choice of the near critical or supercritical fluid will depend upon the solubility of the organic compound in the fluid since a function of the supercritical or near-critical fluid is to act as a solvent for the reagents. In some cases, however, it may be particularly convenient for the near-critical or supercritical medium to be simply the alcohol itself (and the other optional reactants when present).

However, the use of a separate near-critical or supercritical fluid is generally preferred.

Particularly favoured media include carbon dioxide, alkanes such as ethane, propane and butane, alkenes, and saturated halocarbons such as hydrofluorocarbons and trichlorofluoromethane.

The near-critical or supercritical reaction medium when present, may be a mixture of two or more fluids having critical points which do not require commercially unacceptable conditions of temperature and pressure in order to achieve the necessary conditions for reaction according to the present invention. For example, a mixture of carbon dioxide with an alkane such as propane may be employed close to or above the theoretical critical point of the mixture.

The alcohol starting material, if not a free- flowing liquid in its normal state may be dissolved in a solvent for the purpose of introducing the alcohol into the reactor. This solvent may be present in addition to or in place of the solvent which is to be the supercritical or near-critical reaction medium.

Alternatively as stated above, the alcohol itself, and any further optional components of the reaction

mixture, may be the near-critical or supercritical reaction medium.

Product formation may be monitored in-si tu by means of IR spectroscopy using a suitably positioned IR cell, or by gas or liquid chromatography performed on samples drawn from the reactor periodically.

We are thus able to form ethers from primary and secondary alcohols with high conversion and good selectivity for n, or branched, products. Surprisingly n, n ethers can be formed by dehydration of n-alcools with little or no rearrangement. In the case of phenolic compounds it is possible by altering the reaction conditions to favour ether formation over Friedel-Crafts alkylation and vice-versa.

We have also demonstrated that it is possible to form acetals and ketals under similar supercritical or near-critical conditions as those employed for ether formation. In the case of branched alcohols, it is also possible to select conditions in which the corresponding alkene is obtained in high yield in preference to the ether product.

There is also little requirement for excess alcohols to be used in the process of the present invention because of the excellent conversion rates; this simplifies purification of the products.

The reactions are performed using. a continuous flow reactor (preferably tubular reactor). It is therefore possible to control the residence time, and also the other reaction parameters independently. This allows greater control of the reaction resulting in more efficient and also more selective reactions than can be achieved in the conventional processes.

The present invention will now be described by way

of example only with reference to Figure 1. Figure 1 is a schematic diagram of a continuous flow reactor according to the present invention.

The substrate 1, which is dissolved in an appropriate inert solvent (for example an alkane such as hexane) if it is not a free-flowing liquid or if it is a solid, is pumped into mixer 2 which is a mixing vessel. The mixer 2 may include a stirrer (not shown).

However, mixing of substrate 1 and fluid 3 may equally be effected without the use of stirrer. The substrate 1 is mixed with fluid 3 which is delivered from a reservoir via a pump to mixer 2. Where required, an additional reagent can be added via the same or another pump to mixer 2 with the ratio of the reagents being independently varied as required.

The temperature and the pressure in the mixer is adjusted to a temperature and pressure close to or above the critical point of the fluid 3 as required.

Heating means are provided in the mixer for this purpose. The mixture is then passed into reactor 5 which contains a heterogeneous catalyst (not shown) fixed on a suitable support. A means of controlling the pressure in the reactor is also included. The catalyst provides a source of Bronsted acid to the reaction mixture as the pressurised mixture passes over the catalyst.

After an appropriate mean residence time in reactor 5, the fluid 3, which now contains the product, is passed into pressure reduction unit 6. The products 7 are removed via a take-off tap after passing through pressure reduction unit 6. The flow rate of reactants through reactor 5 is controlled by a valve (not shown) in pressure reducer 6. Fluid 3 is vented through a relief pipe 8 for subsequent recycling or

disposal.

The parameters of a typical reaction might involve a system pressure of 40-300 bar (this will of course depend on the reaction medium) and the flow rate of the reagents is typically in the range of 0.5 to 20.0 ml/min. The reactor temperature is usually in the range of 30-350°C (again this will depend on the reaction medium) and the flow rate of supercritical or near critical fluid is usually in the range of 0.65 to 1.65 1/min of gaseous flow at atmospheric pressure-for a 10ml reactor.

The present invention will now be illustrated by the following examples in which the temperature is the catalyst bed temperature and the solvent flow is given as gaseous flow at atmosphere pressure.

Example 1 iso-Ether Formation Isopropyl alcohol was exposed to a Deloxan ASP 1/7 acid catalyst (available from Degussa-Huls AG) under the conditions given below in a continuous flow reactor.

The volume of the reactor was 10 ml and the flow rate of the solvent was 0.65 L/min. Temp (°C) Pressure Substrate Flow Solvent Yield (Bar) Rate (ml/min) (%) 200 200 0.5 CO2 29

Example 2 n-Ether Formation n-Butanol was exposed to an Amberlyst 15 acid catalyst under the conditions given below in a continuous flow reactor. The volume of the reactor was 20 ml and the flow rate of the solvent was 0.65 L/min.

Temp (°C) Pressure Substrate Flow Solvent Yield (Bar) Rate (ml/min) (%)<BR> 200°C 200 0. 5 CO2 60 Example 3 Mixed Ether Formation Isopropanol and n-propanol in the ratio of 1.2 parts isopropanol to 1.0 parts n-propanol were exposed to a Deloxan ASP 1/7 acid catalyst (Degussa-Huls AG) under the conditions given below in a continuous flow reactor.

The reactor volume was 20 ml and the flow rate of the solvent was 0.65 L/min. Temp (°C) Pressure Substrate Flow Solvent Yield (Bar) Rate (ml/min) (%) 150 200 0.5 CO2 41

Example 4 Cyclic Ether 1,4-butanediol was exposed to a Deloxan ASP 1/7 acid catalyst (available from Degussa-Huls AG) under the conditions given below in a continuous flow reactor.

The reactor volume was 10ml and the solvent flow rate was 0.65 L/min.

Temp (°C) Pressure Substrate Flow Solvent Yield (atm) Rate (ml/min) (%) 200 200 0.5 C02 100 150 100 0.5 C02 100 125 100 0.5 CO2 87 200 100 2. 0 CO2 93 Example 5 Mono-Etherification of Diols 1,6-Hexanediol and methanol in the ratio of 1.0 part 1,6 hexanediol to 1.1 part methanol were exposed to a Deloxan ASP 1/7 acid catalyst (Degussa-Huls AG) under the conditions given below in a continuous flow reactor.

The reactor volume was 10 ml and the flow rate of the solvent was 0.65 L/min. Temp (°C) Pressure Substrate Flow Solvent Yield Di-ether (atm) Rate (ml/min) (0-.) (%) 100 200 0.5 CO2 32 13 <BR> <BR> 200 200 0. 5 C02 65 6

Example 6 Acetal Formation 1,2-Ethanediol and benzaldehyde in the ratio of 2.0 parts benzaldehyde to 1.0 part 1,2-ethanediol were exposed to a Deloxan ASP 1/7 acid catalyst (Deguss=Hüls AG) under the conditions given below in a continuous flow reactor. The reactor volume was 10 ml and the flow rate of solvent was 0.65 L/min.

Temp (°C) Pressure Substrate Flow Solvent Yield (atm) Rate (ml/min) (%) 100 200 0.5 CO2 89 <BR> <BR> <BR> <BR> <BR> 200 200 0.5 CO2 80<BR> Example 7 Ketal Formation 1,2-Ethanediol and acetone in the ratio of 2.0 parts acetone to 1.0 part 1,2 ethanediol were exposed to a Deloxan c ASP 1/7 acid catalyst (Degussa-Huls AG) under the conditions given below in a continuous flow reactor.

The reactor volume was 10 ml and the flow rate of solvent was 0.65 L/min. Temp (°C) Pressure Substrate Flow Solvent Yield (atm) Rate (ml/min) (%) 150 200 0.5 C02 61

Example 8 Alkene Formation 2-Pentanol was exposed to a Deloxan ASP 1/7 catalyst (Degussa-Huls AG) under the conditions given below in a continuous flow reactor. The reactor volume was 10ml and the flow rate of solvent was 0.65 L/min. OH 2-Pentene Temp (°C) Pressure Substrate Flow Solvent Pentene (atm) Rate (ml/min) (%) 200 200 0.5 CO2 100