United States Patent Application: 0100130752
In a recent dispatch, now accessible on the West Virginia Coal Association's web site via the link:
"'Synthesis of Cyclic Carbonates from Epoxides and Carbon Dioxide Using Bimetallic Aluminum Complexes'; Michael North; University of Newcastle; UK; Abstract: Over the last six years, highly active catalysts for the synthesis of cyclic carbonates from epoxides and carbon dioxide have been developed. The compatibility of the catalysts with waste carbon dioxide present in power station flue gas has been investigated and studies to enhance the commercial applicability of the catalysts by reducing the cost of their production carried out. Instead of just dumping ... carbon dioxide, it is attractive to consider utilizing it in the large scale production of chemicals (carbon capture and utilization, CCU). In this way, an unwanted waste product can be turned into a valuable commodity";
we made further report of technology being developed wherein Carbon Dioxide, perhaps as specifically "present in power station flue gas", can be reacted with a type of compound, "epoxides", in the presence of a specific type of catalyst, identified in the full report as "aluminum-salen" complexes, and, in a process requiring relatively low energy to drive the needed reactions, be made to form "cyclic carbonates", a class of compounds which can be further utilized as the basic raw material for the manufacture of certain plastics, most specifically "polycarbonate", a family of plastic compounds with absolutely vast application potentials that has been limited in use primarily because of the expense of having to rely on traditional petroleum-based and other, manufactured, feedstock as the raw material for it's manufacture.
As we noted in that dispatch, the "epoxides" needed for reaction with Carbon Dioxide can be derived from natural, botanical products, and thus represent an additional, albeit indirect, route of CO2 use and consumption in such processes for the synthesis of "cyclic carbonates". But, in reports to follow, we will demonstrate that technologies are now being developed in other nations of the world wherein the required epoxides can themselves be synthesized from, in part, Carbon Dioxide.
However, herein, we wanted to demonstrate, via a collection of three United States Patent Applications, that Michael North at Great Britain's University of New Castle wasn't just speculating about the potentials for such Carbon Dioxide utilization technologies in "Synthesis of Cyclic Carbonates from Epoxides and Carbon Dioxide Using Bimetallic Aluminum Complexes". They have formalized practical descriptions of the processes, even down to explaining how the needed "Aluminum Complexes" can be manufactured.
As seen, first, in excerpts from the initial link in this dispatch to:
"United States Patent Application 20100130752 - Synthesis of Cyclic Carbonates
Patent US20100130752 - SYNTHESIS OF CYCLIC CARBONATES - Google Patents
Date: May 27, 2010
Inventor: Michael North, New Castle Upon Tyne, Great Britain
Assignee: University of New Castle
Abstract: A process for the production of cyclic carbonates comprising contacting an epoxide with carbon dioxide in the presence of a dimeric aluminium(salen) catalyst, and a co-catalyst (as further specified and described).Claims: A process for the production of cyclic carbonates comprising contacting an epoxide with carbon dioxide in the presence of a dimeric aluminium(salen) catalyst, and a co-catalyst ... .
(We are compelled to condense our excerpts in the extreme. The bulk of the claims is given over to a description of the process that refers in chemical shorthand, utterly indecipherable to us mere mortals, to accompanying documentation that is inaccessible in versions of patent applications published on the web by the US Patent and Trademark Office. It's all there, but, if we wanted a complete understanding, we would have to acquire all of the support documents and engage the services of a college chemistry professor to summarize them for us in more concise, understandable terms.)
The process ... wherein the reaction is carried out at a temperature of between 0 and 40 C. and a pressure of between 0.5 and 2 atmospheres ... for 3 to 24 hours.
(Again, it is a relatively low-energy, i.e., low-cost, process that can be carried out at, basically, ambient temperatures and pressures; although a little time, no doubt dependent to a certain extent on the temperature and pressure, is required.)
Description: The present invention relates to a process for synthesising cyclic carbonates from epoxides and carbon dioxide using aluminium(salen) complexes as catalysts. The invention also provides a method for manufacturing aluminium(salen) complexes and further provides novel aluminium(salen) complexes.
(Actually, as we will see, the "method for manufacturing aluminium(salen) complexes" is dealt with in a separate US Patent Application.)
Cyclic carbonates are commercially important products currently manufactured on a multi-tonne scale for use as ... monomers for polymer synthesis. The synthesis of cyclic carbonates generally involves the reaction of epoxides with carbon dioxide, and hence could be used to sequestrate carbon dioxide, thus reducing the level of greenhouse gases in the atmosphere."
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Again, we are compelled to edit and summarize our excerpts in the extreme. The full Claims and Description sections would be intelligible only to people like your nerdy younger brother who got straight A's in science and chemistry, and whom your folks became so proud of, while you just slinked off to the mines to dig Coal so you could buy that new pickup truck you always wanted.
Further, and again, the full Disclosure makes heavy reference to support documentation that just isn't available to us; but, which is, nonetheless, quite real. And, the reality of this CO2-recycling technology is confirmed by a second United States Patent Application, made for related processes, by the same University of New Castle scientist. As can be seen in:
"United States Patent Application: 0110015409 - Synthesis of Cyclic Carbonates
Patent US20110015409 - SYNTHESIS OF CYCLIC CARBONATES - Google Patents
Date: January 20, 2011
Inventor: Michael North, New Castle Upon Tyne, Great Britain
Assignee: University of New Castle
Abstract: A dimeric aluminium(salen) catalyst of formula (as specified and referenced).
Claims: A process for production of cyclic carbonates comprising contacting an epoxide with carbon dioxide in a presence of a dimeric aluminium(salen) catalyst (as specified and described).
(The above, almost inanely-brief, excerpt is actually a summation of Claim 17. The preceding Claims are, because of the chemical shorthand employed, totally indecipherable to non-specialists; especially without the illuminating support documents that are, by reference, included in this patent application.)
The use of a dimeric aluminium (salen) catalyst ... for the production of cyclic carbonates from epoxides.
(Again, "the production of cyclic carbonates from epoxides" is accomplished by reacting the "epoxides" with Carbon Dioxide.)
Preferred epoxides are ethylene oxide ..., propylene oxide ..., butylene oxide ..., and styrene oxide ... .
(And, again, we will be demonstrating in future reports how at least some of the needed, and even "preferred", epoxides can themselves be synthesized from Carbon Dioxide.)
Description: The present invention relates to a process for synthesising cyclic carbonates from epoxides and carbon dioxide using aluminium(salen) complexes as catalysts. The invention also provides novel aluminium(salen) complexes, and their synthesis.
Cyclic carbonates are commercially important products currently manufactured on a multi-tonne scale for use as ... monomers for polymer synthesis. The synthesis of cyclic carbonates generally involves the reaction of epoxides with carbon dioxide, and hence could be used to sequestrate carbon dioxide, thus reducing the level of greenhouse gases in the atmosphere.
In a third aspect of the invention, there is provided a process for the production of dimeric aluminium(salen) catalysts."
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Although the full Disclosure of "United States Patent Application 0110015409 - Synthesis of Cyclic Carbonates" does go into some detail concerning the specified "dimeric aluminium(salen) catalysts" for this Carbon Dioxide utilization technology, those catalysts are more fully treated and described in:
"United States Patent Application: 0110319634 - Aluminum Complexes and their Use in the Synthesis of Cyclic Carbonates
Date: December 29, 2011
Inventor: Michael North, New Castle Upon Tyne, Great Britain
Assignee: University of New Castle
Abstract: Dimeric aluminium catalysts of formula (specified): and their use in catalysing the synthesis of cyclic carbonates from epoxides and carbon dioxide.
Claims: A dimeric aluminium catalyst of formula (as specified and described).
A catalyst ... wherein the catalyst is immobilized on a solid support, (and, a) process for the production of cyclic carbonates comprising contacting an epoxide with carbon dioxide in the presence of a catalyst according to (the claims) with a co-catalyst capable of supplying (Chlorine, Bromine or Iodine ions).
A process for the production of cyclic carbonates comprising contacting an epoxide with carbon dioxide in the presence of a catalyst according to (the claims).
Description: The present invention relates to aluminum ... complexes and their use as catalysts for synthesising cyclic carbonates from epoxides and carbon dioxide.
In one aspect of the present invention, there is provided a process for the production of cyclic carbonates comprising contacting an epoxide with carbon dioxide in the presence of a dimeric aluminium(acen) or aluminium(salacen) catalyst ... .
This reaction has the advantage that it may be carried out at easily accessible temperatures of between 0 and 40 C and pressures of (under) 2 atmospheres. ... Preferably, the reaction temperature lies between 20 and 30 C. Yields of over 50% may be achieved with short reaction times of 3 to 24 hours, using commercially viable amounts of catalyst ... . In some cases, yields of over 70% or over 90% may be achieved under these conditions.
The reaction may also be carried out in a flow reactor, wherein the reaction is continuous.
In some embodiments, the carbon dioxide may be supplied heated ... ."
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Gosh, anyone know where we can get some "heated" Carbon Dioxide?
Actually, it remains unclear to us, even though in our earlier report of "Synthesis of Cyclic Carbonates from Epoxides and Carbon Dioxide Using Bimetallic Aluminum Complexes" it's indicated that these technologies were developed for the utilization of "waste carbon dioxide present in power station flue gas", how much separation and purification of the CO2 present in Coal-fired power plant exhaust might be needed before it would be suitable for use in these processes.
But, again, as Inventor Michael North indicates, and as seen separately in:
http://stage.iupac.org/
Cyclic Carbonates, as can be made herein from Carbon Dioxide, can be employed in the synthesis of Polycarbonates; and, according to the Lund University of Sweden, of Polyurethanes, as well. Both are polymers of such broad use and vast utility they are almost now essential commodities in nearly every conceivable manufacturing sector. Truly significant amounts of CO2 could be profitably and productively, and permanently, "sequestered" in their syntheses, with truly significant opportunities also appending to anyone who had both a ready supply of Carbon Dioxide and the will to start putting that CO2 to work in the synthesis of Cyclic Carbonates, as described and disclosed herein by the University of New Castle