A-Olefins manufacture

Linear a-olefins, 20 414. See also Linear higher a-olefins manufacture of, 17 713-724 world producers of, 17 710t Linear blending value (LBV), 12 412—413 Linear burning rate, 10 720 Linear collider, 23 862... 

Sheet production, of methacrylic ester polymers, 16 282 Sheet silicon, 23 40—41 Shell a-olefin manufacture, 17 713—714. See also Shell higher olefins process (SHOP)... 

Although synthetic lubrication oil production amounts to only about 2% of the total market, volume has been increasing rapidly (67). Growth rates of the order of 20% per year for poly( a-olefin)s, 10% for polybutenes, and 8% for esters (28) reflect increasing automotive use and these increases would accelerate if synthetics were adopted for factory fill of engines by automotive manufacturers. The estimated production of poly( a-olefin)s for lubricants appears to be approximately 100,000 m /yr, esters 75,000, poly(alkylene glycol)s 42,000, polybutenes 38,000, phosphates 20,000, and dialkyl benzene 18,000 (28,67). The higher costs reflected in Table 18 (18,28) have restricted the volume of siUcones, chlorotrifluoroethylene, perfluoroalkylpolyethers, and polyphenyl ethers. 

High density polyethylene (HDPE) is defined by ASTM D1248-84 as a product of ethylene polymerisation with a density of 0.940 g/cm or higher. This range includes both homopolymers of ethylene and its copolymers with small amounts of a-olefins. The first commercial processes for HDPE manufacture were developed in the early 1950s and utilised a variety of transition-metal polymerisation catalysts based on molybdenum (1), chromium (2,3), and titanium (4). Commercial production of HDPE was started in 1956 in the United States by Phillips Petroleum Company and in Europe by Hoechst (5). HDPE is one of the largest volume commodity plastics produced in the world, with a worldwide capacity in 1994 of over 14 x 10 t/yr and a 32% share of the total polyethylene production. 

The chemical iadustry manufactures a large variety of semicrystalline ethylene copolymers containing small amounts of a-olefins. These copolymers are produced ia catalytic polymerisation reactions and have densities lower than those of ethylene homopolymers known as high density polyethylene (HDPE). Ethylene copolymers produced ia catalytic polymerisation reactions are usually described as linear ethylene polymers, to distiaguish them from ethylene polymers containing long branches which are produced ia radical polymerisation reactions at high pressures (see Olefin POLYMERS, LOWDENSITY polyethylene). 

DualZieg ler Catalysts. The choice of a particular a-olefin ia commercial LLDPE manufacture is dictated by two factors the desired resia... 

Most Kaminsky catalysts contain only one type of active center. They produce ethylene—a-olefin copolymers with uniform compositional distributions and quite narrow MWDs which, at their limit, can be characterized by M.Jratios of about 2.0 and MFR of about 15. These features of the catalysts determine their first appHcations in the specialty resin area, to be used in the synthesis of either uniformly branched VLDPE resins or completely amorphous PE plastomers. Kaminsky catalysts have been gradually replacing Ziegler catalysts in the manufacture of certain commodity LLDPE products. They also faciUtate the copolymerization of ethylene with cycHc dienes such as cyclopentene and norhornene (33,34). These copolymers are compositionaHy uniform and can be used as LLDPE resins with special properties. Ethylene—norhornene copolymers are resistant to chemicals and heat, have high glass transitions, and very high transparency which makes them suitable for polymer optical fibers (34). 

Chromium Oxide-Based Catalysts. Chromium oxide-based catalysts were originally developed by Phillips Petroleum Company for the manufacture of HDPE resins subsequendy, they have been modified for ethylene—a-olefin copolymerisation reactions (10). These catalysts use a mixed sihca—titania support containing from 2 to 20 wt % of Ti. After the deposition of chromium species onto the support, the catalyst is first oxidised by an oxygen—air mixture and then reduced at increased temperatures with carbon monoxide. The catalyst systems used for ethylene copolymerisation consist of sohd catalysts and co-catalysts, ie, triaLkylboron or trialkyl aluminum compounds. Ethylene—a-olefin copolymers produced with these catalysts have very broad molecular weight distributions, characterised by M.Jin the 12—35 and MER in the 80—200 range. 

Higher a-olefins can also be polymerized with cationic initiators to fiquid oligomeric materials with isomerized stmctures. These fiquids are manufactured commercially and used as lubricating oils. 

Butene. Commercial production of 1-butene, as well as the manufacture of other linear a-olefins with even carbon atom numbers, is based on the ethylene oligomerization reaction. The reaction can be catalyzed by triethyl aluminum at 180—280°C and 15—30 MPa ( 150 300 atm) pressure (6) or by nickel-based catalysts at 80—120°C and 7—15 MPa pressure (7—9). Another commercially developed method includes ethylene dimerization with the Ziegler dimerization catalysts, (OR) —AIR, where R represents small alkyl groups (10). In addition, several processes are used to manufacture 1-butene from mixed butylene streams in refineries (11) (see BuTYLENEs). 

Most linear a-olefins are produced from ethylene. Ethylene-based capacity in 1993 was 2,196,000 t, compared to only 30,000 t for fatty alcohol-based manufacture. 

Synthesis and Manufacture of Amines. The chemical and busiaess segments of amines (qv) and quaternaries are so closely linked that it is difficult to consider these separately. The majority of commercially produced amines origiaate from three amine raw materials natural fats and oils, a-olefins, and fatty alcohols. Most large commercial manufacturers of quaternary ammonium compounds are fully back-iategrated to at least one of these three sources of amines. The amines are then used to produce a wide array of commercially available quaternary ammonium compounds. Some iadividual quaternary ammonium compounds can be produced by more than one synthetic route. 

OleFns and Fatty Alcohols. Alkylbenzyldimethylammonium (ABDM) quatematies are usually prepared from a-olefin or fatty alcohol precursors. Manufacturers that start from the fatty alcohol usually prefer to prepare the intermediate alkyldimethylamine direcdy by using dimethylamine and a catalyst rather than from fatty alkyl chloride. Small volumes of dialkyldimethyl and alkyltrimethyl quatematies in the Cg—range are also manufactured from these precursors (Fig. 4). 

A considerable amount of hydrobromic acid is consumed in the manufacture of inorganic bromides, as well as in the synthesis of alkyl bromides from alcohols. The acid can also be used to hydrobrominate olefins (qv). The addition can take place by an ionic mechanism, usually in a polar solvent, according to Markownikoff s rule to yield a secondary alkyl bromide. Under the influence of a free-radical catalyst, in aprotic, nonpolar solvents, dry hydrogen bromide reacts with an a-olefin to produce a primary alkyl bromide as the predominant product. Primary alkyl bromides are useful in synthesizing other compounds and are 40—60 times as reactive as the corresponding chlorides (6). 

These siUca-supported catalysts demonstrate the close connections between catalysis in solutions and catalysis on surfaces, but they are not industrial catalysts. However, siUca is used as a support for chromium complexes, formed either from chromocene or chromium salts, that are industrial catalysts for polymerization of a-olefins (64,65). Supported chromium complex catalysts are used on an enormous scale in the manufacture of linear polyethylene in the Unipol and Phillips processes (see Olefin polymers). The exact stmctures of the surface species are still not known, but it is evident that there is a close analogy linking soluble and supported metal complex catalysts for olefin polymerization. 

The higher molecular weight unbranched C10-C18 n-olefins—not only a-olefins but also n-olefins with internal double bonds, so-called n-vj/-olefins—are important initial products for the manufacture of anionic surfactants, e.g., linear alkylbenzenes or olefinsulfonates. These linear C10-C18 olefins are manufactured technically by the following procedures ... 

Coordination-catalyzed ethylene oligomerization into n-a-olefins. The synthesis of homologous, even-numbered, linear a-olefins can also be performed by oligomerization of ethylene with the aid of homogeneous transition metal complex catalysts [26]. Such a soluble complex catalyst is formed by reaction of, say, a zero-valent nickel compound with a tertiary phosphine ligand. A typical Ni catalyst for the ethylene oligomerization is manufactured from cyclo-octadienyl nickel(O) and diphenylphosphinoacetic ester ... 

Not only the linear Cl0-Cl8 a-olefins but also the linear C10-Cl8 olefins with internal double bonds, the so-called -v /-olefins, are of great importance in surfactant chemistry, n-a-Olefins and n-y-olefins have the same suitability for the manufacture of linear alkylbenzenes, the most important synthetic anionic surfactants, by alkylation of benzene. Nowadays medium molecular weight n- /-olefins are industrially produced by two processes the catalytic dehydrogenation of the corresponding n-alkanes [4,28] and the cometathesis of low and high molecular weight n-v /-olefins, obtained by double-bond isomerization of the isomeric n-a-olefins [29]. 

The oligomerization leads to a mixture of a-olefins. In the first step the a-olefins are isolated by distillation. These a-olefins are of a suitable side chain for use in the manufacture of surfactants (starting material for alcohols and deriva-... 

For a discussion of modern methods of olefin manufacture by pyrolysis, consult the paper by Ennis and co-workers (5). 

Transition metal catalysis plays a key role in the polyolefin industry. The discovery by Ziegler and Natta of the coordination polymerization of ethylene, propylene, and other non-polar a-olefins using titanium-based catalysts, revolutionized the industry. These catalysts, along with titanium- and zirconium-based metallocene systems and aluminum cocatalysts, are still the workhorse in the manufacture of commodity polyolefin materials such as polyethylene and polypropylene [3-6],... 

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