Vinyl acetate from acetylene

Vinyl compounds. Vinyl chloride (prepared from acetylene and hydrogen chloride) 3 ields polyvinyl chloride (P.V.C.), which is employed as a rubber substitute and for other purposes. Vinyl acetate (from... 

Liquid- and vapor-phase processes have been described the latter appear to be advantageous. Supported cadmium, zinc, or mercury salts are used as catalysts. In 1963 it was estimated that 85% of U.S. vinyl acetate capacity was based on acetylene, but it has been completely replaced since about 1982 by newer technology using oxidative addition of acetic acid to ethylene (2) (see Vinyl polymers). In western Europe production of vinyl acetate from acetylene stiU remains a significant commercial route. 

Vinyl acetate is the most important of this family of compounds. Produced from acetic acid and either ethylene or acetylene, vinyl acetate finds uses in production of polyvinyl acetate, polyvinyl alcohol, polyvinyl butyrot. and polyvinyl chloride copolymers. 

A recent study indicates that if the Wacker process proves to be substantially cheaper than the acetylene route, no more vinyl acetate plants will be built in the United States, based on the latter process (38). Table XV gives estimated production costs for manufacturing vinyl acetate. Several companies are building or have already built plants to manufacture vinyl acetate from ethylene. These include Distillers Co., Ltd., British Celanese, Imperial Chemical Industries, and Celanese Corp., to name only a few. 

Desulfurization of petroleum feedstock (FBR), catalytic cracking (MBR or FI BR), hydrodewaxing (FBR), steam reforming of methane or naphtha (FBR), water-gas shift (CO conversion) reaction (FBR-A), ammonia synthesis (FBR-A), methanol from synthesis gas (FBR), oxidation of sulfur dioxide (FBR-A), isomerization of xylenes (FBR-A), catalytic reforming of naphtha (FBR-A), reduction of nitrobenzene to aniline (FBR), butadiene from n-butanes (FBR-A), ethylbenzene by alkylation of benzene (FBR), dehydrogenation of ethylbenzene to styrene (FBR), methyl ethyl ketone from sec-butyl alcohol (by dehydrogenation) (FBR), formaldehyde from methanol (FBR), disproportionation of toluene (FBR-A), dehydration of ethanol (FBR-A), dimethylaniline from aniline and methanol (FBR), vinyl chloride from acetone (FBR), vinyl acetate from acetylene and acetic acid (FBR), phosgene from carbon monoxide (FBR), dichloroethane by oxichlorination of ethylene (FBR), oxidation of ethylene to ethylene oxide (FBR), oxidation of benzene to maleic anhydride (FBR), oxidation of toluene to benzaldehyde (FBR), phthalic anhydride from o-xylene (FBR), furane from butadiene (FBR), acrylonitrile by ammoxidation of propylene (FI BR)... 

Table 11.1 lists economic data concerning methods for the manufacture of vinyl acetate from acetylene and ethylene. 

Vinyl acetate monomer can be synthesized by the reaction of acetic acid with either acetylene or with ethylene. For the production of vinyl acetate from acetic acid and acetylene, the following process was adopted a gaseous mixture of acetylene and acetic acid was reacted at about 200°C in the presence of active carbon impregnated with zinc acetate... 

The last U.S. plant for the production of vinyl acetate from acetylene shut down in the late 1980s, though this simple reaction, over zinc acetate at about 200°C, is still in use in Europe and Japan. The production of vinyl... 

Abstract In this chapter, an exothermic catalytic reaction process is simulated by using computational mass transfer (CMT) models as presented in Chap. 3. The difference between the simulation in this chapter from those in Chaps. 4,5, and 6 is that chemical reaction is involved. The source term in the species conservation equation represents not only the mass transferred from one phase to the other, but also the mass created or depleted by a chemical reaction. Thus, the application of the CMT model is extended to simulating the chemical reactor. The simulation is carried out on a wall-cooled catalytic reactor for the synthesis of vinyl acetate from acetic acid and acetylene by using both c — Sc model and Reynolds mass flux model. The simulated axial concentration and temperature distributions are in agreement with the experimental measurement. As the distribution of lx shows dissimilarity with Dj and the Sci or Pri are thus varying throughout the reactor. The anisotropic axial and radial turbulent mass transfer diffusivities are predicted where the wavy shape of axial diffusivity D, along the radial direction indicates the important influence of catalysis porosity distribution on the performance of a reactor. 

Liu [2] used the CMT (P- — two-equation model (abbreviated as two-equation model) for simulating a catalytic reactor with cooling jacket for producing vinyl acetate from acetic acid and acetylene as described below. 

The reactor simulated is a wall-cooled fixed-bed catalytic reactor reported by Valstar [7] for the synthesis of vinyl acetate from acetic acid and acetylene with zinc acetate on activated carbon as catalyst as given in Sect. 7.1.2. 

Vinyl ethers are prepared in a solution process at 150—200°C with alkaH metal hydroxide catalysts (32—34), although a vapor-phase process has been reported (35). A wide variety of vinyl ethers are produced commercially. Vinyl acetate has been manufactured from acetic acid and acetylene in a vapor-phase process using zinc acetate catalyst (36,37), but ethylene is the currently preferred raw material. Vinyl derivatives of amines, amides, and mercaptans can be made similarly. A/-Vinyl-2-pyrroHdinone is a commercially important monomer prepared by vinylation of 2-pyrroHdinone using a base catalyst. 

The principal chemical markets for acetylene at present are its uses in the preparation of vinyl chloride, vinyl acetate, and 1,4-butanediol. Polymers from these monomers reach the consumer in the form of surface coatings (paints, films, sheets, or textiles), containers, pipe, electrical wire insulation, adhesives, and many other products which total biUions of kg. The acetylene routes to these monomers were once dominant but have been largely displaced by newer processes based on olefinic starting materials. 

Vinyl acetate (ethenyl acetate) is produced in the vapor-phase reaction at 180—200°C of acetylene and acetic acid over a cadmium, 2inc, or mercury acetate catalyst. However, the palladium-cataly2ed reaction of ethylene and acetic acid has displaced most of the commercial acetylene-based units (see Acetylene-DERIVED chemicals Vinyl polymers). Current production is dependent on the use of low cost by-product acetylene from ethylene plants or from low cost hydrocarbon feeds. 

Most of the vinyl acetate produced in the United States is made by the vapor-phase ethylene process. In this process, a vapor-phase mixture of ethylene, acetic acid, and oxygen is passed at elevated temperature and pressures over a fixed-bed catalyst consisting of supported palladium (85). Less than 70% oxygen, acetic acid, and ethylene conversion is realized per pass. Therefore, these components have to be recovered and returned to the reaction zone. The vinyl acetate yield using this process is typically in the 91—95% range (86). Vinyl acetate can be manufactured also from acetylene, acetaldehyde, and the hquid-phase ethylene process (see Vinyl polymers). 

Phenylisoxazole has been obtained from the ethylene acetal of /3-benzoylacetaldehyde (300 R = Ph) and hydroxylamine (60ZOB954), and also from benzonitrile iV-oxide and acetylene (49G703), vinyl chloride (70S344), vinyl acetate (62BSF2215) or nitroethylene (76S612). 

With each succeeding year in the 1950s and 1960s there was a swing away from coal and vegetable sources of raw materials towards petroleum. Today such products as terephthalic acid, styrene, benzene, formaldehyde, vinyl acetate and acrylonitrile are produced from petroleum sources. Large industrial concerns that had been built on acetylene chemistry became based on petrochemicals whilst coal tar is no longer an indispensable source of aromatics. 

Vinyl acetate is polymerized to poly(vinyl acetate), (PVAc), which finds use in adhesives and water-based paints. Some PVAc is hydrolyzed (reacted with water) to poly(vinyl alcohol) (PVA) for textile sizing, adhesives, and paper coatings. A substantial amount of U.S.-produced vinyl acetate is exported. Prior to 1970, almost all vinyl acetate was made from acetylene. Now none of it is. 

Until the 1960s, acrylonitrile was, like vinyl acetate, made from acetylene (by reaction with hydrogen cyanide), but research on catalysts in the 1950s led to the much less costly route shown above. 

The commercial process for the production of vinyl acetate monomer (VAM) has evolved over the years. In the 1930s, Wacker developed a process based upon the gas-phase conversion of acetylene and acetic acid over a zinc acetate carbon-supported catalyst. This chemistry and process eventually gave way in the late 1960s to a more economically favorable gas-phase conversion of ethylene and acetic acid over a palladium-based silica-supported catalyst. Today, most of the world s vinyl acetate is derived from the ethylene-based process. The end uses of vinyl acetate are diverse and range from die protective laminate film used in automotive safety glass to polymer-based paints and adhesives. 

In 1969, 90% of vinyl acetate was manufactured by this process. By 1975 only 10% was made from acetylene, and in 1980 it was obsolete. Instead, a newer method based on ethylene replaced this old acetylene chemistry. A Wacker catalyst is used in this process similar to that for acetic acid. Since the acetic acid can also be made from ethylene, the basic raw material is solely ethylene, in recent years very economically advantageous as compared to acetylene chemistry. An older liquid-phase process has been replaced by a vapor-phase reaction run at 70-140 psi and 175-200°C. Catalysts may be (1) C—PdCb—CuCb, (2) PdClj—AI2O3, or (3) Pd—C, KOAc. The product is distilled water, acetaldehyde, and some polymer are... 

Acetic acid is an important industrial chemical. The reaction of acetic acid with hydroxyl-containing compounds, especially alcohols, results in the formation of acetate esters. The largest use of acetic acid is in the production ofvinyl acetate (Figure 1.1). Vinyl acetate can be produced through the reaction of acetylene and acetic acid. It is also produced from ethylene and acetic acid. Vinyl acetate is polymerized into polyvinyl acetate (PVA), which is used in the production of fibers, films, adhesives, and latex paints. 

In addition to the polymer, copolymers of vinyl chloride with other vinyl monomers are important commercial plastics. Copolymers with vinyl acetate, which is produced from acetylene and acetic acid, are widely used in sheeting, surface coating, and filaments, being less brittle and more readily soluble in organic solvents than is pure polyvinyl chloride. Copolymers with acrylonitrile are also of importance for the production of... 

Catalysts used to convert ethylene to vinyl acetate are closely related to those used to produce acetaldehyde from ethylene. Acetaldehyde was first produced industrially by the hydration of acetylene, but novel catalytic systems developed cooperatively by Farbwerke Hoechst and Wacker-Chemie have been used successfully to oxidize ethylene to acetaldehyde, and this process is now well established (7). However, since the largest use for acetaldehyde is as an intermediate in the production of acetic acid, the recent announcement of new processes for producing acetic acid from methanol and carbon monoxide leads one to speculate as to whether ethylene will continue to be the preferred raw material for acetaldehyde (and acetic acid). 

Other catalytic reactions carried out in fluidized-bed reactors are the oxidation of naphthalene to phthalic anhydride [2, 6, 80] the ammoxidation of isobutane to mcthacrylonitrilc [2] the synthesis of maleic anhydride from the naphtha cracker C4 fraction (Mitsubishi process [81, 82]) or from n-butane (ALMA process [83], [84]) the reaction of acetylene with acetic acid to vinyl acetate [2] the oxychlorination of ethylene to 1,2-di-chloroethane [2, 6, 85, 86] the chlorination of methane [2], the reaction of phenol with methanol to cresol and 2,6-xylenol [2, 87] the reaction of methanol to gasoline... 

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