This invention relates generally to a method for preparing borohydride salts from a slurry of sodium borohydride and a sodium alkoxide in a liquid hydrocarbon.

Processes for production of potassium borohydride from alkoxide-containing mixtures are known, but are inefficient in that they do not result in useful products from both the borohydride and alkoxide components. For example, U.S. Pat. No. 2,720,444 describes production of potassium borohydride from a mixture containing sodium borohydride and sodium methoxide. However, the process combines the sodium borohydride with 10% excess potassium hydroxide, and no data are provided on the disposition of the excess potassium hydroxide, nor is it suggested that high-purity sodium methoxide could be isolated as a coproduct.

The problem addressed by this invention is to provide a process for producing a metal borohydride, other than sodium borohydride, and sodium methoxide.

The present invention is directed to a method for producing a metal borohydride, M(BH₄)_n, where n is 1 or 2, from a slurry of sodium borohydride and a sodium alkoxide in a liquid hydrocarbon. The method comprises steps of: (a) combining said slurry with 0.99 to 1.01 equivalents of a metal salt, M(X)_n; and methanol; wherein M is Li, K, Rb, Cs, Mg, Ca, Sr or Ba; and X is halide, alkoxide or acetate; (b) filtering to collect M(BH₄)_n; and (c) separating oil and methanol liquid phases to obtain sodium methoxide in methanol solution.

Unless otherwise specified, all percentages herein are stated as weight percentages and temperatures are in °C.

In one embodiment of the invention, the metal, M, is Li, K, Ca, Sr or Ba. In a preferred embodiment of the invention, M is K. In one embodiment of the invention, the anion, X, in the metal salt is alkoxide, chloride, bromide or iodide. In a preferred embodiment of the invention, X is chloride or alkoxide. Particularly preferred metal salts include potassium methoxide, potassium chloride, calcium chloride, strontium chloride and barium chloride.

The liquid hydrocarbon used in the present invention is any hydrocarbon which is liquid at 25°C. Suitable hydrocarbons include alkanes, e.g., mineral oil; and aromatics. Mineral oil is particularly preferred. Preferably, the amount of liquid hydrocarbon is from 0.01 L/g NaBH₄ to 10 L/g NaBH₄, alternatively from 0.2 L/g NaBH₄ to 1 L/g NaBH₄.

In one embodiment of the invention in which X is an alkoxide, the alkoxide is a C₁-C₁₂ alkoxide, alternatively a C₁-C₈ alkoxide, alternatively a C₁-C₄ alkoxide. In one preferred embodiment, the alkoxide is methoxide, ethoxide, isopropoxide or t-butoxide. Methoxide is particularly preferred. Alkoxides can be generated from hydroxides and alcohols.

In one embodiment of the invention, the amount of metal salt used is from 0.995 to 1.005 equivalents with respect to the amount of sodium borohydride in the slurry, alternatively about one equivalent. In one embodiment of the invention, the sodium alkoxide and sodium borohydride in the slurry are in a molar ratio of about 3:1, alkoxide:borohydride.

For the case where M is a monovalent metal (n=1), and sodium alkoxide and sodium borohydride in the slurry are in a molar ratio of about 3:1, alkoxide:borohydride, an equation describing the reaction is as follows:



         3NaOR + NaBH₄ + MX → MBH₄ + NaX + 3NaOR



MBH₄ is insoluble in the methanol/hydrocarbon reaction medium, and thus will form a precipitate. NaX may also be insoluble, depending on the nature of X. In cases where NaX is soluble, the MBH₄ can be isolated by filtration, with the filtrate containing a hydrocarbon phase, and a methanol/NaX phase. When M is divalent (n=2) and X is chloro, the reaction is as follows:



         6NaOR + 2NaBH₄ + MCl₂ → M(BH₄)₂ + 2NaCl + 6NaOR



In this case, both M(BH₄)₂ and NaCl are insoluble. NaCl can be removed from the metal borohydride by washing the solids with water.

Preferably, the reaction temperature is from 0°C to 50°C, alternatively from 15°C to 40°C. Preferably, the amount of methanol added is from 10 g/g NaBH₄ to 50 g/g NaBH₄, alternatively from 12 g/g NaBH₄ to 30 g/g NaBH₄.

This three-phase slurry was initially filtered through a grade "B" ultra-coarse glass frit (70 - 100 µm) but no solids were caught by the filter. The slurry was then passed through a grade "E" extra-fine glass frit (2 to 8 µm). This filtration was done under a dynamic oil pump vacuum. The resulting solid was washed multiple times with 742 grams of hexane and the resulting solid was dried under vacuum at room temperature.

The resulting two liquids were separated using a separatory funnel.

The two liquids and solids were analyzed for % NaOCH₃ (NaOMe), %KBH, % NaOH, % oil and by ICP analysis. Solids g, (yield) Oil Layer g (yield) CH₃OH Layer g, (yield) Recovery Wt sample(g) 46.31 525.24 658.2 % KBH 86.21, 86.25 0,0 0.35,0.34 ICP,Na 4.34% 29 ppm 10.14 % ICP, K 61.46 2.6 ppm 967 ppm ICP, B 19.42 4.4 ppm 937 ppm % NaOMe/ total alkalinity N/A 0,0 26.19.26.13 % NaOH 7.52,7.52 % Oil 1964 ppm N/A 1184 ppm Grams KBH 39.82 (82.1 %) 2.30g 42.12/48.50=86.85 Grams Oil 525.24 525.24/553=94.89 Grams NaOMe/total alkalinity 4.63 172.11 (86.5 %) 176.74/198.94=89.26

These results demonstrate that KBH and NaOMe both can be isolated with good purity and yield, especially with regard to K contamination in NaOMe. Solids g, (yield) Oil Layer g (yield) CH₃OH Layer g, (yield) Recovery Wt sample(g) 55.44 408.82 700.51 % KBH 75.422 0.014 0.341 ICP, Na - - - ICP, K - - - ICP, B - - - % NaOMe/ total alkalinity 0 23.060 % NaOH 16.403 0 % Oil - N/A - Grams KBH 41.814 (89.43 %) 0 2.38 44.19 / 46.75 = 94.52 Grams Oil 530.82 530.82/533.76= 99.45 Grams NaOMe/total alkalinity 9.31 165.32 (86.30 %) 174.63/191.55= 91.17