Process for recovery of polyol fatty acid polyesters

Claim 2

In a solvent-free, low temperature process for synthesizing polyol fatty acid polyesters by transesterification of a polyol with a fatty acid ester to produce a crude reaction product containing a dark, liquid mixture of the product polyol fatty acid polyester, fatty acid alkyl esters, alkali metal fatty acid soaps and color-forming impurities, the improvement which comprises treating the crude reaction product to obtain the polyol fatty acid polyesters contained therein by the steps of contacting the crude reaction product with an aqueous washing medium while maintaining the resultant mixture at a pH of from 7 to about 12, inclusive, in the presence of an emulsion decreasing organic solvent at a temperature of from about 25° C. to about 100° C. for a period of time of from about 15 minutes to at least three hours to dissolve substantial amounts of fatty acid soaps and color-forming impurities in the aqueous phase, allowing the phases to settle into an organic phase and an aqueous phase and separating the organic from the aqueous phase.

Claim 3

The process of claim 1 in which said solvent is a polar solvent.

Claim 4

The process of claim 1 in which said solvent is selected from acetone, methyl ethyl ketone, methanol, ethanol and isopropanol.

Claim 5

The process of claim 1 in which said polyol fatty acid polyester is selected from sorbitol, xylitol and sucrose.

Claim 6

The process of claim 1 in which said polyol fatty acid polyester is sucrose.

Claim 7

The process of claim 1 in which said aqueous washing medium is selected from water and aqueous solutions of alkali metal compounds.

Claim 8

The process of claim 1 in which said washing medium is water.

Claim 9

The process of claim 1 in which said washing medium is an aqueous solution of an alkali metal compound.

Claim 10

The process of claim 8 in which said aqueous alkali metal compound is selected from aqueous solutions of sodium hydroxide, potassium hydroxide, sodium carbonate, potassium carbonate, sodium bicarbonate and potassium bicarbonate.

Claim 11

The process of claim 8 in which said aqueous alkali metal compound is a dilute solution of the alkali metal compound.

Claim 12

The process of claim 1 in which said polyol is treated with from 10 to about 100 percent by weight based on the crude reaction product containing said polyol of said aqueous washing medium.

Claim 13

The process of claim 1 in which said polyol is treated with from about 20 to about 40 percent by weight based on the crude reaction product containing said polyol of said aqueous washing medium.

Claim 14

The process of claim 1 in which the weight ratio of said aqueous washing medium to said organic solvent ranges from 1:1 to about 10:1.

Claim 15

The process of claim 1 in which the weight ratio of said aqueous washing medium to said organic solvent ranges from about 3:1 to about 7:1.

Claim 16

The process of claim 1 in which the steps of contacting, allowing phases to settle and separating the phases is carried out for at least three successive times.

Claim 17

The process of claim 15 in which the three successive washings are conducted using from 20 to about 40 percent of an aqueous washing medium selected from dilute aqueous alkali metal compounds and having a weight ratio of an aqueous washing medium to organic solvent of from 3:1 to 7:1 in the first wash, from 5:1 to 15:1 in the second wash and from 15:1 to not greater than 25:1 in the third and subsequent wash.

Claim 18

The process of claim 1 in which said organic solvent is isopropanol.

Claim 19

The process of claim 1 in which said aqueous washing medium is dilute aqueous caustic.

Claim 20

The process of claim 1 in which said organic solvent is isopropanol and said aqueous washing medium is dilute aqueous caustic.

Claim 21

In a solvent-free, low temperature process for synthesizing polyol fatty acid polyesters consisting essentially of: A. heating a mixture of (i) an aliphatic or aromatic polyol having at least 2 free hydroxyl groups, (ii) a fatty acid alkyl ester, (iii) an alkali metal fatty acid soap, and (iv) a basic catalyst to a temperature and at a pressure sufficient to form a homogeneous melt of partially esterified polyol and unreacted starting materials; B. under the conditions of Step (A), adding excess fatty acid alkyl esters to the reaction product of Step (A) to form the polyol fatty acid polyester; and C. separating the polyol fatty acid polyester from the reaction product of Step (B), the improvement which comprises: (a) contacting the reaction product of Step (B) comprising polyol fatty acid polyester, fatty acid esters, alkali metal fatty acid soaps and color-forming impurities with an aqueous washing medium in the presence of an emulsion decreasing organic solvent, said aqueous washing medium being selected from water and aqueous solutions of alkali metal compounds sufficient to maintain the mixture at a pH in the range of from 7 to 12, inclusive, and said organic solvent being selected from methanol, ethanol, isopropanol, acetone and methylethyl ketone; (b) settling the resultant mixture for a period sufficient to form an aqueous and an organic phase; (c) separating the aqueous phase; (d) repeating Steps (a) through (c) on the resultant organic phase until the aqueous phase is clear; and (e) recovering the polyol fatty acid polyester substantially free of alkali metal fatty acid soaps and color-forming impurities.

Claim 22

In a solvent-free, low temperature process for synthesizing polyol fatty acid polyesters consisting essentially of: A. heating a mixture of (i) an aliphatic or aromatic polyol having at least 2 free hydroxyl groups, (ii) a fatty acid alkyl ester, (iii) an alkali metal fatty acid soap, and (iv) a basic catalyst to a temperature and at a pressure sufficient to form a homogeneous melt of partially esterified polyol and unreacted starting materials; B. under the conditions of Step (A), adding excess fatty acid alkyl esters to the reaction product of Step (A) to form the polyol fatty acid polyester; and C. separating the polyol fatty acid polyester from the reaction product of Step (B), the improvement which comprises: (a) contacting the reaction product of Step (B) comprising polyol fatty acid polyester, fatty acid esters, alkali metal fatty acid soaps and color-forming impurities with an aqueous washing medium in the presence of an emulsion decreasing organic solvent, said aqueous washing medium being selected from water and aqueous solutions of alkali metal compounds sufficient to maintain the mixture at a pH in the range of from 7 to 12, inclusive, and said organic solvent being selected from methanol, ethanol, isopropanol, acetone and methylethyl ketone; (b) settling the resultant mixture for a period sufficient to form an aqueous and an organic phase; (c) separating the aqueous phase; (d) repeating Steps (a) through (c) on the resultant organic phase until the aqueous phase is clear; and (e) recovering the polyol fatty acid polyester substantially free of alkali metal fatty acid soaps and color-forming impurities.

Claim 23

The improved process of claim 20 in which said aqueous washing medium is water.

Claim 24

The improved process of claim 20 in which said aqueous washing medium is selected from aqueous mixtures of sodium carbonate, sodium bicarbonate, potassium hydroxide and sodium hydroxide.

Claim 25

The improved process of claim 20 in which said aqueous washing medium is aqueous sodium hydroxide.

Claim 26

The improved process of claim 1 in which said aqueous washing medium is dilute aqueous sodium hydroxide.

Claim 27

The improved process of claim 20 in which said washing medium is from 10 to about 100% by weight based on the reaction product of said Step (B) and where the weight ratio of the aqueous washing medium to the organic solvent in said Step (a) ranges from 3:1 to 7:1 by weight.

Claim 28

The improved process of claim 20 in which said aqueous washing medium is from 20 to about 50% by weight based on the reaction product of said Step (B).

Claim 29

The improved process of claim 20 in which the organic solvent is isopropanol.

Claim 30

The improved process of claim 20 in which Steps (a) through (c) are carried out three times in succession.

Claim 31

The improved process of claim 28 in which the contacting or washing of the reaction product of said Step (B) is carried out three successive times the first wash having at least a weight ratio of the aqueous washing medium to the organic solvent, ranging from 3:1 to 7:1, the second wash having a weight ratio of the aqueous washing medium to the organic solvent of 5:1 to 15:1, and the third wash having a weight ratio of the aqueous washing medium to the organic solvent ranging from 15:1 to not greater than 25:1.

Claim 32

The improved process of claim 20 in which said aqueous component is dilute aqueous sodium hydroxide and said organic component is isopropanol.

Claim 33

The improved process of claim 20 in which there is employed from 20 to about 50 percent by weight based on the reaction product of said Step (B) of an aqueous washing medium which is dilute caustic, the organic solvent is isopropanol and the contacting or washing of the reaction product of said Step (B) is carried out three sucessive times the first wash having at least a weight ratio of the aqueous washing medium to the organic solvent, ranging from 3:1 to 7:1, the second wash having a weight ratio of the aqueous washing medium to the organic solvent of 5:1 to 15:1, and the third wash having a weight ratio of the aqueous washing medium to the organic solvent ranging from 15:1 to not greater than 25:1.

Claim 34

The improved process of claim 20 in which the polyol is a disaccharide.

Claim 35

The improved process of claim 20 in which said polyol is selected from the group consisting of sucrose, xylitol and sorbitol.

Claim 36

The improved process of claim 33 in which the aqueous washing medium is dilute caustic, the organic solvent is isopropanol and the reaction product of said Step (B) is contacted with from 20 to about 50% by weight of the aqueous washing medium based on the reaction product of said Step (B).

Claim 37

The improved process of claim 20 in which the fatty acid alkyl esters are fatty acid methyl esters.

Claim 38

The improved process of claim 20 in which the methyl esters are derived from natural oils selected from the group consisting of soybean oil, sunflower oil, safflower oil and corn oil.

Claim 39

The improved process of claim 36 in which the reaction product of said Step (B) is contacted with from 20 to about 50% by weight of an aqueous washing medium based on the reaction product of said Step (B), which is dilute aqueous sodium hydroxide and said organic solvent being isopropanol.

Claim 40

The improved process of claim 20 in which the polyol is sucrose.

Claim 41

The improved process of claim 38 in which the reaction product of said Step (B) is contacted with from 20 to about 50% by weight of an aqueous washing medium based on the reaction product of said Step (B), which is dilute aqueous sodium hydroxide said organic solvent being isopropanol, and the contacting or washing of the reaction product of said Step (B) being carried out at least three successive times the first wash having at least a weight ratio of the aqueous washing medium to the organic solvent, ranging from 3:1 to 7:1, the second wash having a weight ratio of the aqueous washing medium to the organic solvent of 5:1 to 15:1, and the third wash having a weight ratio of the aqueous washing medium to the organic solvent ranging from 15:1 to not greater than 25:1.