Exothermic reactions acid temperature control

A typical flow diagram for pentaerythritol production is shown in Figure 2. The main concern in mixing is to avoid loss of temperature control in this exothermic reaction, which can lead to excessive by-product formation and/or reduced yields of pentaerythritol (55,58,59). The reaction time depends on the reaction temperature and may vary from about 0.5 to 4 h at final temperatures of about 65 and 35°C, respectively. The reactor product, neutralized with acetic or formic acid, is then stripped of excess formaldehyde and water to produce a highly concentrated solution of pentaerythritol reaction products. This is then cooled under carefully controlled crystallization conditions so that the crystals can be readily separated from the Hquors by subsequent filtration. 

In contrast to the silver process, all of the formaldehyde is made by the exothermic reaction (eq. 23) at essentially atmospheric pressure and at 300—400°C. By proper temperature control, a methanol conversion greater than 99% can be maintained. By-products are carbon monoxide and dimethyl ether, in addition to small amounts of carbon dioxide and formic acid. Overall plant yields are 88—92%. 

Another method of preparing mercuric acetate is the oxidation of mercury metal using peracetic acid dissolved in acetic acid. Careful control of the temperature is extremely important because the reaction is quite exothermic. A preferred procedure is the addition of approximately half to two-thirds of the required total of peracetic acid solution to a dispersion of mercury metal in acetic acid to obtain the mercurous salt, followed by addition of the remainder of the peracetic acid to form the mercuric salt. The exothermic reaction is carried to completion by heating slowly and cautiously to reflux. This also serves to decompose excess peracid. It is possible and perhaps more economical to use 50% hydrogen peroxide instead of peracetic acid, but the reaction does not go quite as smoothly. 

Hydrogenations can be carried out in batch reactors, in continuous slurry reactors, or in fixed-bed reactors. The material of constmetion is usually 316 L stainless steel because of its better corrosion resistance to fatty acids. The hydrogenation reaction is exothermic and provisions must be made for the effective removal or control of the heat a reduction of one IV per g of C g fatty acid releases 7.1 J (1.7 cal), which raises the temperature 1.58°C. This heat of hydrogenation is used to raise the temperature of the fatty acid to the desired reaction temperature and is maintained with cooling water to control the reaction. 

Solution Process. With the exception of fibrous triacetate, practically all cellulose acetate is manufactured by a solution process using sulfuric acid catalyst with acetic anhydride in an acetic acid solvent. An excellent description of this process is given (85). In the process (Fig. 8), cellulose (ca 400 kg) is treated with ca 1200 kg acetic anhydride in 1600 kg acetic acid solvent and 28—40 kg sulfuric acid (7—10% based on cellulose) as catalyst. During the exothermic reaction, the temperature is controlled at 40—45°C to minimize cellulose degradation. After the reaction solution becomes clear and fiber-free and the desired viscosity has been achieved, sufficient aqueous acetic acid (60—70% acid) is added to destroy the excess anhydride and provide 10—15% free water for hydrolysis. At this point, the sulfuric acid catalyst may be partially neutralized with calcium, magnesium, or sodium salts for better control of product molecular weight. 

Hydrochloric acid may conveniently be prepared by combustion of hydrogen with chlorine. In a typical process dry hydrogen chloride is passed into a vapour blender to be mixed with an equimolar proportion of dry acetylene. The presence of chlorine may cause an explosion and thus a device is used to detect any sudden rise in temperature. In such circumstances the hydrogen chloride is automatically diverted to the atmosphere. The mixture of gases is then led to a multi-tubular reactor, each tube of which is packed with a mercuric chloride catalyst on an activated carbon support. The reaction is initiated by heat but once it has started cooling has to be applied to control the highly exothermic reaction at about 90-100°C. In addition to the main reaction the side reactions shown in Figure 12.6 may occur. 

Nitration Hazards arise from the strong oxidizing nature of the nitrating agents used (e.g. mixture of nitric and sulphuric acids) and from the explosive characteristics of some end products Reactions and side reactions involving oxidation are highly exothermic and may occur rapidly Sensitive temperature control is essential to avoid run-away... 

The reaction between bis(dimethylamino)methane and trifluoroacetic acid is very exothermic. If the temperature is carefully controlled, a colorless solution remains when the addition is complete. 

When an acetonitrile/sulphuric acid mixture is heated to 53°C, it gives rise to an exothermic reaction that could not be controlled, and brought the temperature in the reactor to 160°C. The same happens when adding sulphur trioxide to the same mixture, but in this case the reaction goes out of control at a temperature starting at 15°C. This behviour is explained by acetonitrile poly-merisation. 

In absence of diluent or other effective control of reaction rate, the sulfoxide reacts violently or explosively with the following acetyl chloride, benzenesul-fonyl chloride, cyanuric chloride, phosphorus trichloride, phosphoryl chloride, tetrachlorosilane, sulfur dichloride, disulfur dichloride, sulfuryl chloride or thionyl chloride [1], These violent reactions are explained in terms of exothermic polymerisation of formaldehyde produced under a variety of conditions by interaction of the sulfoxide with reactive halides, acidic or basic reagents [2], Oxalyl chloride reacts explosively with DMSO at ambient temperature, but controllably in dichloromethane at -60°C [3]. 

Addition of the dehydrated salt to acetic anhydride caused an exothermic reaction which accelerated to explosion. Presence of acetic acid (including that produced by hydrolysis of the anhydride by the hydrate water) has a delaying effect on the onset of violent reaction, which occurs where the proportion of anhydride to acid (after hydrolysis) exceeds 0.37 1, with an initial temperature above 35°C. Mixtures of dichromate (30 g) with anhydride-acid mixtures (70 g, to give ratios of 2 1, 1 1, 0.37 1) originally at 40°C accelerated out of control after 18, 43 and 120 min, to 160, 155 and 115°C, respectively. 

The key to a controlled molecular weight build-up, which leads to the control of product properties such as glass transition temperature and melt viscosity, is the use of a molar excess of diisopropanolamine as a chain stopper. Thus, as a first step in the synthesis process, the cyclic anhydride is dosed slowly to an excess of amine to accommodate the exothermic reaction and prevent unwanted side reactions such as double acylation of diisopropanolamine. HPLC analysis has shown that the reaction mixture after the exothermic reaction is quite complex. Although the main component is the expected acid-diol, unreacted amine and amine salts are still present and small oligomers already formed. In the absence of any catalyst, a further increase of reaction temperature to 140-180°C leads to a rapid polycondensation. The expected amount of water is distilled (under vacuum, if required) from the hot polymer melt in approximately 2-6 h depending on the anhydride used. At the end of the synthesis the concentration of carboxylic acid groups value reaches the desired low level. 

An example of a highly exothermic reaction carried out in this manner is provided by the manufacture of dodecylbenzene sulphonic acid. The reactor is charged with dodecylbenzene and 20% oleum is fed in continuously at a rate which is regulated to give a uniform temperature during the sulphonation reaction. The conversion is thus effectively controlled by the rate of oleum addition rather than the rate of the chemical reaction. 

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