Reactor Bayer

A number of the above features are included to reduce flocculation and the formation of wall polymer. While fundamental knowledge on flocculation or the formation of wall polymer is inadequate to establish the effects of all reactor design variables, the features of the Bayer reactor seem qualitatively correct. More fundamental work will be necessary to develop an understanding of the influence of design on reactor performance and product quality. 

Subsequent separation of this solvent imposes substantial capital and operating cost penalties. A Bayer AG patent (37) claims use of a solvent in which DNT is soluble, but in which the TDA is practically insoluble. This allows separation and recycle of the solvent to the reactor without any distillation process. 

Silicones, an important item of commerce, are widely available commercially (9,494). The principal manufacturers of silicone operate direct-process reactors to produce dimethyl dichi orosilane and, ultimately, polydimethyl siloxane. Typical plants produce more than 450 t per year. The siUcone industry is a global enterprise in the 1990s, with principal producers in the United States (Dow Coming, GE, and OSi), Europe (Wacker Chemie, Hbls, Rhc ne-Poulenc, and Bayer), and Southeast Asia (Shin-Etsu, Toshiba SiUcones, and Dow Coming, Japan). Table 15 Hsts the approximate sales of the principal producers for 1991. 

Pareek, V., M.P. Brungs, and A.A. Adesina, Photocausticization of Spent Bayer liquor A Pilot-Scale Study. Advances in Environmental Research, 2003. 7(2) p. 411-420. Bertola, F., M. Vanni, and G. Baldi, Application of Computational Fluid Dynamics to Multiphase Flow in Bubble Columns. International journal of Chemical Reactor Engineering, 2003. 1 p. A3. 

In the flowsheet of alumina production by the Bayer process, aluminum is precipitated from an aqueous solution as aluminum hydroxide. The hydroxide is dried in rotary furnaces. In recent times, fluidized-bed reactors have been deployed which yield practically nonhygroscopic alumina. The dissociation of aluminum hydroxide occurs in steps,... 

The production of aluminum actually involves several steps. Bauxite is the ore that contains aluminum oxide (Al Oj) used to produce aluminum. Impurities of iron, sulfur, silicon and other elements are removed from bauxite using the Bayer process to produce purified alumina. The Bayer process, patented in 1887 by Austrian Karl Josef Bayer (1847-1904), involves pulverizing bauxite and treating it with a hot sodium hydroxide solution to produce sodium alu-minate (NaA102). Sodium aluminate is then placed in a reactor in which temperature and pressure can be varied to precipitate out impurities. The sodium aluminate solution is then hydrolyzed to produce purified alumina ... 

The gas-phase process, successfully commercialized independently by Bayer and USI,417 involves passing a mixture of ethylene, acetic acid and oxygen over a supported palladium catalyst contained in a multitubular reactor at 150 °C and about 5-10 atm pressure. The overall yield in vinyl acetate is about 92%, and the major by-product is C02. The catalyst consists of a palladium salt (e.g. Na2PdCl4) deposited on silica (or alumina) in the presence of a cocatalyst (e.g. HAuC14), reduced and impregnated with potassium acetate before use.384,418 The lifetime of the catalyst is about 2... 

The Bayer Ketazine process is based on the reaction of chloramine with ammonia in the presence of acetone at pH 12 to 14. NaOCl, acetone and a 20% aqueous solution of ammonia (at a mole ratio of 1 2 20, respectively) are fed to a reactor at 35°C and 200 kPa to make the aqueous dimethyl ketazine solution. Excess ammonia and acetone are removed in a series of columns and recycled to the reactor. The ketazine solution is distilled to make a hydrazine hydrate containing 64% hydrazine. A sketch of this process is shown in Figure 18.4132. Use of NaOCl is estimated to be 3.5 pounds per pound of hydrazine. 

The catalytic gas-phase hydrogenation processes for nitrobenzene can be carried out using a fixed-bed or a fluidized bed reactor. Bayer and Allied work with nickel sulfide catalysts at 300°C to 475°C in a fixed bed. The selectivity to aniline is more than 99%. The catalytic activity slowly decreases due to carbon... 

This process may be carried out by a batch or a continuous process. The continuous process is more effective for large plants. Both processes wash the crude nitrobenzene with water. The crude nitrobenzene is fed to a distillation system to separate the water, benzene and dinitrobenzene. This process requires reactor cooling and a system for sulfuric acid reconcentration. Yields by the continuous process are 95% to 96% of theoretical. Bayer used this process in the United States until it discontinued nitrobenzene production in 1994258. ... 

Anisole acetylation, which was one of the main reactions investigated, was first shown to be catalysed by zeolite ten years ago by Bayer (13), which was confirmed by Harvey et al. (14), then by Rhodia (15). Large pore zeolites and especially those with a tridimensional pore structure such as HBEA and HFAU were found to be the most active at 80°C, in a batch reactor with an anisole/acetic anhydride molar ratio of 5 and after 6 hours reaction, the yield in methoxyacetophenone (MAP) was close to 70% with HBEA and HFAU zeolites, to 30% with HMOR and 12% with HMFI. With all the zeolites and also with clays and heteropolyacids, the selectivity to the para-isomer was greater than 98%, which indicates that this high selectivity is not due to shape selective effects but rather to the reaction mechanism (electrophilic substitution). The lower conversion observed with HMOR can be related to the monodimensional pore system of this zeolite which is very sensitive to blockage by heavy secondary products. Furthermore, limitations in the desorption of methoxyacetophenone from the narrow pores of HMFI are probably responsible for the low activity of this intermediate pore size zeolite. 

Two types of polyvinylpyrrolidones (PVP-Bayer, Leverkusen, Germany) have been found beneficial to cell growth in spinner cultures, and a mixed molecular weight PVP has been found to protect hybridoma cells against shear injury in a bubble column reactor (Handa, 1986). 

In the Bayer process, ground bauxite is digested with aqueous sodium hydroxide (200 to 350 g/L sodium hydroxide) at temperatures of 140 to 250°C in autoclaves or in continuous tube reactors, in which the hydrated aluminum hydroxide is dissolved as sodium aluminate. The iron-containing very finely divided so-called red mud is then separated in thickening and filter units and washed. Ca. 1 to 2 t of red mud is produced per t aluminum oxide. 

Continuous digestion of bauxite with sodium hydroxide in autoclaves or tubular reactors at 140 to 250°C under pressure using the Bayer process... 

In the industrial process employed by Bayer AG, Germany, m-cresol and propylene, both in the liquid state, are pumped through a pressure tube reactor, filled with activated alumina. The process is performed at a molar ratio of m-cresol propylene of 1.07 at 350-360°C, 5kg/cm and LHSV of 0.25 hr. The reaction product consists of 25% m-cresol, 60% th3nnol and 15% other products. Thymol of 99% + purity is obtained by rectification of the crude product [1]. 

The role of micro(structured)-reactors for process intensification (PI) has been widely commented on in previous sections, as well as the strong interest on this sector of various iimovative companies like DuPont, BASF, Merck, UOP, Shell, Schering, Degussa-Hiils, Bayer, and so on. However, due to the relevance of this area for PI... 

The first industrial plant using n-butane to manufacture maleic anhydride was started up by Monsanto in 1984. At the time, 20 per cent of the maleic anhydride production capacity of this company switched from benzene to butane. Since then, three other manufacturers in the United States (Amoco, Ashland and Denka Chemical), and two in Western Europe (Bayer and Huh) have followed a similar procedure, so that ail maleic anhydride produced today in the United States is based on butane feedstock and nearly 50 per cent of worldwide installed capacity operates by this method. The n-butane is oxidized in the vapor phase, in a multi-tube reactor, on a fixed bed of catalyst based on phosphorus, vanadium and iron, deposited on a silica/alumina support... 

---