Technical Field

The present invention relates to preparation of 2,3,5-trimethylbenzo- quinone and particularly to the field of photooxidation of 2,3,5-trimethylphenol.

Background of the invention

2,3,5-Trimethylbenzoquinone is a key intermediate in the production of 2,3,5-trimethylhydroquinone or alpha-tocopherol, respectively The direct chemical oxidation of 2,3,5-trimethylphenol to 2,3,5-trimethyl- benzoquinone is generally difficult resulting in moderate yields and selectivities.

It has been proposed by Murtinho D. et al. , J. Chem. Soc. Perkin Trans. 2, 2000, 2441-2447 to photooxidize 2,3,5-trimethylphenol to obtain 2,3,5-trimethyl- benzoquinone using oxygen in the presence of a photosensitizer. In particular, it discloses methylene blue as photosensitizer for 1 ,5-dihydroxynaphthalene in a mixture of acetonitrile and dichloromethane. However, as a result of moderate yield of 78 to 82 %, it has been suggested using porphyrin type photosensitizers instead. Such porphyrin compounds are rather expensive and not readily commer cially available. On the other hand acetonitrile as well as dichloromethane are solvents which have significant ecological and ecotoxicological disadvantages. Furthermore, it is known that it is much more difficult to oxidize phenols than naphthols.

Methylene blue is often used as photosensitizer in photoreactions and is commercially readily available from various suppliers.

Summary of the invention

Therefore, the problem to be solved by the present invention is to offer an efficient method of synthesizing 2,3,5-trimethylbenzoquinone from 2,3,5-trimethyl- phenol in high yield and selectivity. It has been found that the photooxidation according to claim 1 offers an efficient way of solving this problem.

In the present invention methylene blue can be used, which is a readily available and cost-effective a very attractive photosensitizer and get the desired product not only in very high yield at high conversion but also in a very high selectivity. Particularly advantageous is that the process can be performed in the absence of any chlorinated solvents. Hence, said process is highly attractive for industrial application.

Further aspects of the invention are subject of further independent claims. Particularly preferred embodiments are subject of dependent claims.

Detailed description of the invention

The present invention relates to a process of manufacturing the compound of the formula (I) from the compound of the formula (II) by photooxidation using oxygen and a photosensitizer of the formula (III) wherein R ⁸ , R ^8' , R ^8" and R ^8'" independently from each other represent either a H, or a C _1-4 alkyl group; or wherein R ⁸ and R ^8' and/or R ^8" and R ^8"' form together with N a five or six membered ring; with the proviso that at least one of the residues R ⁸ , R ^8' , R ^8" and R ^8'" is different from H; and X represents an anion; in solvent mixture of water and at least one C1-8 alkanol or at least one C2-4 alkylene diol; and using light which has a peak wavelength (Amax) in its spectrum in the range of between 580 and 780 nm.

For sake of clarity, some terms as used in the present document are defined as follows:

In the present document, a “C _x-y -alkyl” group is an alkyl group comprising x to y carbon atoms, i.e. , for example, a C-i-3-alkyl group is an alkyl group compri sing 1 to 3 carbon atoms. The alkyl group can be linear or branched. For example -CFI(CFl3)-CFl2-CFl3 is considered as a C4-alkyl group.

Analogously, a C _x-y alkanol, respectively a C _x-y alkylene diol, is an alcohol having one, respectively two, OFI groups where the alcohol has an alkyl respecti vely alkylene group comprising x to y carbon atoms.

In case identical labels for symbols or groups are present in several formulae, in the present document, the definition of said group or symbol made in the context of one specific formula applies also to other formulae which comprises the same said label.

The peak wavelength is the wavelength where the spectrum reaches its highest intensity.

In the said process 2,3,5-trimethylphenol (=compound of formula (II)) is photooxidized to yield 2,3,5-trimethylbenzoquinone (=compound of formula (I)).

2,3,5-trimethylphenol is a known chemical and is commercially available in large quantities from different suppliers. In the photooxidation a photosensitizer of the formula (III) is used wherein R ⁸ , R ^8' , R ^8" and R ^8'" independently from each other represent either a H, or a C _1-4 alkyl group; or wherein R ⁸ and R ^8' and/or R ^8" and R ^8'" form together with N a five or six membered ring; with the proviso that at least one of the residues R ⁸ , R ^8' , R ^8" and R ^8'" is different from H; and X represents an anion.

In one embodiment, R ⁸ and R ^8' and/or R ^8" and R ^8"' form together -(CH ₂ )5- or -(CH ₂ )2-NH-(CH ₂ )2- or -(CH ₂ ) ₂ -N(CI- ₄ alkyl)-(CH ₂ ) ₂ - or -(CH ₂ ) ₂ -S-(CH ₂ ) ₂ - or -(CH ₂ ) ₂ -0-(CH ₂ ) ₂ - .

It is further preferred that R ⁸ = R ^8" and/or R ^8' = R ^8'" . More preferred is that R8= _R8' = _{R8 "} = _R8"'

More preferably, the substituent R ⁸ , R ^8' , R ^8" and R ^8'" represent a C1-4 alkyl group, even more preferably R ⁸ =R ^8' =R ^8" =R ^8'" = methyl or ethyl.

Most preferably R ⁸ =R ^8, =R ^8" =R ^{8 '} = CH _3.

In formula (III) X- represents an anion. The role of the anion is to counter balance the charge of the cation which is represented in the above formula by the part within the brackets ([)(]). Therefore, in principle any anion can be used.

Preferably, X- represents a halide, most preferably a chloride.

Preferably, the compound of formula (III) is methylene blue. Further preferred is the compound of formula (III) in the form of a double salt with zinc chloride, particularly a double salt of methylene blue with zinc chloride or in the form of a hydrate, preferably methylene blue hydrate (CAS: 122965-43-9). It has been found that the photosensitizer of formula (III) is particularly suited in the photooxidation of the compound of formula (II). It is essential that for the above photooxidation light is used which has a peak wavelength (Amax) in its spectrum in the range of between 580 and 780 nm.

In one preferred embodiment light is used which has a peak wavelength (Amax) in its spectrum in the range of between 625 and 740 nm. This corresponds to a light which is perceived as red.

In another, more preferred, embodiment light is used which has a peak wavelength (Amax) in its spectrum in the range of between 585 and 625 nm. This corresponds to a light which is perceived as orange. This light is mainly of the high wavelength range of the visible spectrum.

In a further preferred embodiment the light used is characterized so that more than 80% of the light has a wavelength of between 525 and 780 nm, prefe rably more than 80% of the light has a wavelength of between 525 and 700 nm, more preferably more than 65% of the emitted light has a wavelength of between 550 and 650 nm.

It is, therefore, important that the light used has no significant amount of light having a wavelength below 580 nm in its spectrum. It is essential that light of the colours green, blue and violet or colours having significant amounts green, blue and violet in their spectrum have been found not to be suited for the above photooxidation.

In one embodiment, the light which is used for the photooxidation can be realized by filtering the undesired light wavelengths from a light source. For example a light source having a multichromatic or white emission can be filtered by a filter which blocks off the undesired wavelength. There are different possibility of such filters known and commercially avai lable such as absorption, dichroic, monochromatic, band-pass, short-pass or wedge filters, using different physical methods for filtration of light.

Particularly useful are absorption or cut-off filters.

Figure 1a represents a schematic representation of this embodiment. The light source (1) emits radiation of different wavelengths, which have the desired wavelengths (2a) and undesired wavelengths (2b). The light source is preferably a white light, more preferably a white LED. A filter (6) is positioned between light source (1) and the photoreactor which has a transparent wall (4). The filter (6) filters the light of undesired wavelengths to provide a light which has a peak wavelength (Amax) in its spectrum in the range of between 580 and 780 nm. The filter (6) is preferably an "orange filter" or "red filter", i.e. a filter that allows only light with a wavelength of between 585 and 625 nm or between 625 and 740 nm to pass through. The reaction mixture (3), which comprises at least oxygen and the compound of formula (II) and the solvent mixture of water and at least one Ci- ₈ alkanol or at least one C2-4 alkylene diol, is inside the photoreactor (5).

By the photoreaction a compound of formula (I) is produced by photo chemical reaction from compound of formula (II) and oxygen, particular in a gas mixture comprising at least 20 % by volume of oxygen.

A specific preferred example of this embodiment is a white LED. The light of which is filtered in such a way that all light which is not of the desired wavelengths is blocked or at least significantly absorbed (e.g. using a "orange filter" (allowing transmission of light only of between 585 and 625 nm) or "red filter" (allowing transmission of light only of between 625 and 740 nm)).

So, the light source for the light is preferably a white LED lamp in combi nation with a filter blocking wavelengths below 500 nm, particularly below 625nm.

In a further embodiment, the light which is used for the photooxidation can be produced by a respective light source emitting light of the desired wavelengths. Figure 1b represents a schematic representation of this embodiment. The light source (1 ) emits radiation of the desired wavelengths (2a) to provide a light which has a peak wavelength (Amax) in its spectrum in the range of between 580 and 780 nm. The light source is preferably an orange or red light, more preferably an orange or red LED to provide a light using light which has a peak wavelength (Amax) in its spectrum in the range of between 580 and 780 nm.

The reaction mixture (3), which comprises at least oxygen and the compound of formula (II) and the solvent mixture of water and at least one C1-8 alkanol or at least one C2-4 alkylene diol, is inside the photoreactor (5). By the photoreaction a compound of formula (I) is produced by photochemical reaction from compound of formula (II) and oxygen.

Specific examples of light sources of this embodiments are red LEDs or red or orange Lasers, preferably red or orange LED lamps. Red and orange LED lamps are commercially broadly available. Red and orange LEDs can provide high intensities of red or orange light. In a preferred embodiments a flexible strip having a plurality of individual LEDs incorporated in said strip. This allows to assure radial orientation of the LEDS around a curved surface such as a transparent tube, for example, by simply wrapping, preferably in a helical manner, said strip around the tube.

The photooxidation is performed in a solvent mixture of water and at least one C1-8 alkanol or at least one C2-4 alkylene diol. The C1-8 alkanol is preferably selected from the group consisting of metha nol, ethanol, propanol, isopropanol, butanol, heptanol and hexanol, more prefer ably selected from the group consisting of methanol, ethanol and isopropanol.

The C2-4 alkylene diol is preferably selected from the group consisting of ethane-1 ,2-diol, propane-1 ,2-diol, propane-1 ,3-diol, butane-1, 3-diol, butane-1,4- diol, butan-1 ,2-diol and butane -2, 3-diol, preferably selected from the group consisting of ethane-1 ,2-diol, propane-1 ,2-diol and propane-1 ,3-diol.

It is preferred that the solvent mixture is a mixture of water and at least one C1-8 alkanol or at least one C2-4 alkylene diol form a homogeneous phase. It is preferred that the solvent mixture is a mixture of water and at least one Ci-8 alkanol or at least one C2-4 alkylene diol. More preferred the solvent mixture is a mixture of water and C1-8 alkanol .

More preferably the solvent mixture is a mixture of water and methanol and/or ethanol and/or isopropanol.

It is preferred that the volume ratio of water to the sum of C1-8 alkanol and C2-4 alkylene diol is in the range of between 1:10 and 1:1, particularly between 1 :5 and 1:2.

In a very preferred embodiment the solvent mixture is a mixture of water and methanol, preferably in a volume of water to methanol in the range of 1 :20 to 1 :2, preferably of 1 :10 and 1 :2, more preferably of 1 :6 and 1 :3. ratio, most prefe rably 1:4.

It is a key advantage of the present invention that the photooxidation is made in a solvent mixture consisting of water and at least one C1-8 alkanol or at least one C2-4 alkylene diol, which are ecologically and ecotoxicologically all very favourable solvents and are also economically advantageous. Hence, it is very favourable that the above process is performed in the absence of present of any chlorinated solvent.

It is preferred that the concentration of the compound of formula (II) is in the range of between 0.002 to 2.0 mol/I, preferably 0.01 to 0.2 mol/l at the begin ning of the photooxidation.

Further preferred is that the ratio of the compound of formula (III) to the compound of formula (II) is in the range of between 0.005 and 20 mol%, prefe rably between 0.05 and 20 mol%, more preferably between 0.2 and 10 mol%.

In one embodiment oxygen is used in a form of a mixture comprising oxygen and an inert gas. It is preferred that the amount of oxygen in such a mixture comprising oxygen and an inert gas is at least 15 % by volume, particu larly at least 20 % by volume. Such a mixture may, for example, be a binary mixture such as a mixture oxygen/nitrogen or oxygen/argon or alike. Said mixture can consist of or comprise two or more inert gases. It is particularly preferred to use air as such a mixture comprising oxygen and an inert gas.

In a preferred embodiment, oxygen is used in an substantially pure form, i.e. that the amount of oxygen in the gas is 90% -100% , more preferably 95% - 100%, even more preferably 99% - 100%.

The photooxidation can take place at ambient pressure or under pressure. It is preferred that the oxidation takes place under pressure, particularly under a pressure of more than 2 bar, preferably more than 3 bar, more preferably under a pressure of between 2 and 20 bar.

The photooxidation is performed in a suitable photoreactor. A preferred photoreactor is a flow reactor, particularly in a spiral flow reactor.

The individual components can be introduced separately or as mixture into the photo reactor. Preferably the reaction mixture is prepared before entering into the photo reactor.

In one of the preferred embodiments, an oxygen containing solvent mixture is admixed to compound of formula (II) before entering into the photo reactor.

In another preferred embodiment, the solvent mixture is admixed to compound of formula (II) which already contains oxygen before entering into the photoreactor.

In most preferred embodiments, oxygen is added to a pre-mixture which at least comprises compound of formula (II) and the solvent mixture.

The reaction preferably is processed in such a manner that the pressure of oxygen is controlled by suitable valves and mass flow controller. Such process control equipment and methods for photoreactions using liquids and gases is known by the person skilled in the art. Figures

Figure 1a shows a schematic representation of a photooxidation using a light source and a filter to produce a light with a peak wavelength (Amax) in its spectrum in the range of between 580 and 780 nm.

Figure 1b shows a schematic representation of a photooxidation using a light source with a peak wavelength (Amax) in its spectrum in the range of between 580 and 780 nm. Figure 2a shows a schematic representation of one of the experimental layout.

Figure 2b shows a schematic representation of a different experimental layout.

Figure 2c shows a schematic representation of another different experimental layout.

Figure 3 represents the normalized emission spectrum of light used for the photo oxidation using different filter as well as of the white light in the experiments.

In figure 2a one preferred experimental layout is represented. A vessel comprising a premixture (10), comprising at least the compound of the formula (II) and the photosensitizer of the formula (III) and the solvent mixture of water and at least one Ci- ₈ alkanol or at least one C2-4 alkylene diol, is pumped by a pump (7) into the photoreactor (5). Before entering the photoreactor (5), oxygen (11) is admixed to the premixture forming the photooxidation reaction mixture (3). The amount of oxygen admixed is controlled by a mass flow controller (8). Around the transparent wall (4) of the linear tubular photoreactor (5) the light source (1 ) is arranged, parti cularly in a helical arrangement of LEDs. The light source (1) is preferably a white LED. Between the transparent wall (4) and the light source (1 ) a filter (6) is posit ioned, allowing to provide a light (2a) which has a peak wavelength (Amax) in its spectrum in the range of between 580 and 780 nm. The filter (6) is particularly an orange filter or an red filter, respectively, to provide particularly a light which has a peak wavelength (Amax) in its spectrum in the range of between 585 and 625 nm or 625 and 740 nm, respectively. The photoreactor (5) is preferably a spiral flow reactor. At the outlet of the photoreactor a backpressure regulator (9) is positioned before the product is collected in the collection vessel (12).

This experimental layout, particularly the combination of light source and photo reactor, is preferably used for higher volume photoreactions.

In figure 2b, another preferred experimental layout is represented. A vessel comprising a premixture (10), comprising at least the compound of the formula (II) and the photosensitizer of the formula (III) and the solvent mixture of water and at least one Ci- ₈ alkanol or at least one C2-4 alkylene diol, is pumped by a pump (7) into the photoreactor (5). Before entering the photoreactor (5), oxygen (11) is admixed to the premixture forming the photooxidation reaction mixture (3). The amount of oxygen admixed is controlled by a mass flow controller (8).

Between the transparent wall (4) of the photoreactor (5) and the light source (1), preferably white LEDs, a filter (6) is positioned, allowing to provide a light (2a) which has a peak wavelength (Amax) in its spectrum in the range of between 580 and 780 nm. In the present representation only one light source (1 ) and one filter (6) is shown. It is, of course, possible that several such light sources (1 ), combined with the filter (6) are positioned around the photoreactor (5), in the form of a spiral flow reactor, can be positioned to allow an even irradiation of the whole photoreactor (5). The filter (6) is particularly an orange filter or an red filter, respec tively, to provide particularly a light which has a peak wavelength (Amax) in its spectrum in the range of between 585 and 625 nm or 625 and 740 nm, respecti vely. The light having undesired wavelengths (2b) is filtered off by the filter (6). At the outlet of the photoreactor a backpressure regulator (9) is positioned before the product is finally collected in the collection vessel (12).

This experimental layout, particularly the combination of light source and photoreactor, is preferably used for smaller volume photoreactions.

In figure 2c, another preferred experimental layout is represented. A vessel comprising a premixture (10), comprising at least the compound of the formula (II) and the photosensitizer of the formula (III) and the solvent mixture of water and at least one C1-8 alkanol or at least one C2-4 alkylene diol, is pumped by a pump (7) into the photoreactor (5). Before entering the photoreactor (5), oxygen (11) is admixed to the premixture forming the photooxidation reaction mixture (3). The amount of oxygen admixed is controlled by a mass flow controller (8).

In this embodiment a light source (1), preferably white LED, is arranged in the hollow space formed by the helical windings of the spiral flow reactor (5). Around the a light source (1 ), i.e. between the transparent wall (4) of the photoreactor (5) and the light source (1), a filter (6) is positioned, allowing to provide a light (2a) which has a peak wavelength (Amax) in its spectrum in the range of between 580 and 780 nm. The filter (6) is particularly an orange filter or an red filter, respec tively, to provide particularly a light which has a peak wavelength (Amax) in its spectrum in the range of between 585 and 625 nm or 625 and 740 nm, respecti vely. The light having undesired wavelengths (2b) is filtered off by the filter (6). At the outlet of the photoreactor a backpressure regulator (9) is positioned before the product is finally collected in the collection vessel (12).

This experimental layout, particularly the combination of light source and photo- reactor, is preferably used for smaller volume photoreactions.

In an even further embodiment the light source (1 ) and filter (6) of figures 2b) and 2c) are combined. In other words the filter and light source can be arranged out side of the photoreactor walls arranged inside as well as outside of the space formed by the helical winding of the spiral flow photoreactor (5).

List of reference signs

I Light source

2a Light of desired wavelength

2b Light of undesired wavelength 3 Photooxidation reaction mixture

4 Transparent wall of photoreactor

5 Photoreactor

6 Filter

7 Pump 8 Mass flow controller

9 Backpressure regulator

10 Premixture

I I Oxygen

12 Collection vessel Examples

The present invention is further illustrated by the following experiments.

Experimental layout In the following experiments an experimental layout has been used as schematically represented in figure 2c.

A vessel comprising a premixture (10) of solvent, respectively solvent mixture and the substances to be photooxidized as well as the photosensitizer is pumped by a pump (7) into the photoreactor (5) which is a spiral flow reactor (4.6 mL coil reactor). Before entering the photoreactor (5), oxygen (11) is admixed to the premixture forming the photooxidation reaction mixture (3). The amount of oxygen admixed is controlled by a mass flow controller (8). The light of the light source (1), white LEDs (4000 Im, 32 W, 4100 K) is filtered by respective filter (6) unless mentioned in certain experiments to filter off the light of undesired wavelengths (2b) so that the light of the desired wavelengths (2a) is falling on the transparent walls (4) of the photoreactor (5). The photoreactor (5) is coiled over an inner glass cylinder around a LED lamp (1) cooled with a fan and equipped with the respective filter (6) between LED lamp and the wall of the photoreactor (5). At the outlet of the photoreactor a backpressure regulator (9) is positioned before the product is finally collected in the collection vessel (12). The pressure and flow rate of oxygen as well as the residence time (t _R ) are indicated in the respective experi ments.

The amounts of product formed are determined by GC-FID and ¹ H-NMR using Durene as internal standard.

The light used for the photooxidation experiments are either -white LED light (LSw)

-white LED light filtered by using a green filter (LSg)

-white LED light using an orange filter (LSo). In figure 3, the spectra of the light used for the photooxidation experiments between wavelengths of 325 and 700 nm are shown using the normalized relative intensity ( l _e ,norm ) of the light entering the transparent wall of the photoreactor. Experimental series 1

In the first series 2,3,5-trimethylphenol (=2,3,5 TMP) (0.02 mol/L in ethanol) is photooxidized to 2,3,5-trimethylbenzoquinone (=2,3,5 TMQ) using oxygen (5 bar, 0.810 mL/min) and at 35°C and methylene blue (0.9 mol%) (Flowrate 0.15 mL/min, t _R = 23 min).

The results are compiled in table 1 :

Table 1. Photoreaction of 2,3,5 TMP using different lights

Table 1 shows that in ethanol the use of orange filter is yielding a significantly higher yield at higher selectivity in the desired product.

Experimental series 2

In the second series 2,3,5-trimethylphenol (=2,3,5 TMP) (0.02 mol/L in the respective solvent) is photooxidized to 2,3,5-trimethylbenzoquinone (=2,3,5 TMQ) using oxygen (5 bar, 0.810 mL/min) and at 35°C and methylene blue (0.9 mol%) (Flowrate 0.15 mL/min, t _R = 23 min).

The results are compiled in table 2:

Table 2. Photoreaction of 2,3,5 TMP using oxygen and different solvent and LSo as light source.

*ratio by volume.

Table 2 shows that when using a solvent mixture of water and an alcohol (examples 1, 2 and 3) a significantly higher yield and higher selectivity in the desired product is observed as compared to the comparison examples Re†.4-9.

Experimental series 3

In the third series 2,3,5-trimethylphenol (=2,3,5 TMP) (0.02 mol/L in the respective solvent) is photooxidized to 2,3,5-trimethylbenzoquinone (=2,3,5 TMQ) using air (10 bar, 1.35 mL/min) and at 35°C and methylene blue (0.9 mol%)

(Flowrate 0.25 mL/min, t _R = 16 min).

The results are compiled in table 3: light source. *ratio by volume. Experimental series 4

In the fourth series different substrates have been photooxidized (0.02 mol/L in a solvent mixture of methanol/water of 4/1 (vol/vol)) using air (10 bar, 0.25-1.35 mL/min) and at 35°C and methylene blue (0.9 mol%). The residence time has been selected so to achieve a conversion of more than 99%.

The results are compiled in table 4:

Table 4. Photoreaction o- different substrates using air and LSo as light source.

Table 4 shows that 2,3,5-trimethylphenol shows significantly higher yield into the respective quinone (product) compared to other phenols having similar structure as staring material (substrate) in the photooxidation .

Experimental series 5

In the fifth series 2,3,5-trimethylphenol (=2,3,5 TMP) (0.02 mol/L in a solvent mixture of methanol/water of 4/1 (vol/vol)) using air (10 bar, 1.35 mL/min) and at 35°C and different photosensitizers (0.9 mol%). (Flowrate 0.25 mL/min, t _R = 16 min).

The results are compiled in table 5:

Table 5. Photoreaction of 2,3,5 TMP using air and different photosensitizers and LSo as light source.

Table 5 shows that methylene blue has significantly higher yield and selectivity as compared to other commonly used photosensitizers.

Experimental series 6

In a sixth series different substrates have been photooxidized (0.02 mol/L) in a solvent mixture of methanol/water of 4/1 (vol/vol)) using air (10 bar, 1.35 mL/min) and at 35°C and methylene blue (0.9 mol%). (Flowrate 0.25 mL/min, t _R =

23 min).

The results are compiled in table 6:

Table 6. Photoreaction of different substrates using air and LSo as light source.

The results of table 6 show that 2,3,5-trimethylphenol is transformed to the desired product in much higher amounts than other phenolic compounds under these conditions.