Benzene manufacture

D. M. Litde, Catalytic Reforming, Perm Well Books, Tulsa, OHa., 1985. Refs. 38, 41, 42, and 56 contain excellent descriptions of benzene manufacturing processes. 

U.S. consumption pattern 1999, 3 619t U.S. producers, 3 610t vapor-phase nitration of, 17 257 vinyl chloride reactions with, 25 632 world production by country, 3 611-612t Benzene-based catalyst technology, 15 500 Benzene-based fixed-bed process technology, 15 505-506 Benzene chlorination process, of phenol manufacture, 18 751 m-Benzenedisulfonic acid, 3 602 p-Benzenedisulfonic acid, 3 602 Benzene feedstock, 23 329 Benzene hexachloride, 3 602 Benzene manufacture, toluene in, 25 180-181... 

Catalytic reformates, 13 703 25 168 Catalytic reformers, 13 557 aromatics from, 13 565 effluent separation from, 20 750 Catalytic reforming, 12 403 13 657-658 benzene manufacture, 3 604-606 as a source of toluene, 25 166 Catalytic silver sulfate, 23 536 Catalytic steam reforming reaction,... 

A minor route, which now accounts for 2% of phenol, takes advantage of the usual surplus of toluene from petroleum refining. Oxidation with a number of reagents gives benzoic acid. Further oxidation to p-hydroxybenzoic acid and decarboxylation yields phenol. Here phenol competes with benzene manufacture, also made from toluene when the surplus is large. The last 2% of phenol comes from distillation of petroleum and coal gasification. 

A cracking process, the dealkylation of alkylbenzenes, became an established industrial synthesis for aromatics production. Alkylbenzenes (toluene, xylenes, tri-methylbenzenes) and alkylnaphthalenes are converted to benzene and naphthalene, respectively, in this way. The hydrodealkylation of toluene to benzene is the most important reaction, but it is the most expensive of all benzene manufacturing processes. This is due to the use of expensive hydrogen rendering hydrodealkylation too highly dependent on economic conditions. 

P.R. Brookes and A.G. Livingston, Biological detoxification of 3-chloronitro benzene manufacture wastewater in an extractive membrane bioreactor. Water Res., 28 (1994) 1347. 

Figure 1.7 An initial structure for the manufacture of benzene from toluene and hydrogen incorporating some redundant features.

Benzene was first isolated by Faraday in 1825 from the liquid condensed by compressing oil gas. It is the lightest fraction obtained from the distillation of the coal-tar hydrocarbons, but most benzene is now manufactured from suitable petroleum fractions by dehydrogenation (54%) and dealkylation processes. Its principal industrial use is as a starting point for other chemicals, particularly ethylbenzene, cumene, cyclohexane, styrene (45%), phenol (20%), and Nylon (17%) precursors. U.S. production 1979 2-6 B gals. 

BHC is manufactured by chlorination of benzene in the presence of ultra-violet light. The gamma-isomer is obtained from the crude mixture by selective crystallization, and forms colourless crystals, m.p. I13" C. U.S. production 1980 400 tonnes. 

C, b.p. 81"C. Manufactured by the reduction of benzene with hydrogen in the presence of a nickel catalyst and recovered from natural gase.s. It is inflammable. Used as an intermediate in the preparation of nylon [6] and [66] via caprolactam and as a solvent for oils, fats and waxes, and also as a paint remover. For stereochemistry of cyclohexane see conformation. U.S. production 1980 1 megatonne. 

The most important reaction of the diazonium salts is the condensation with phenols or aromatic amines to form the intensely coloured azo compounds. The phenol or amine is called the secondary component, and the process of coupling with a diazonium salt is the basis of manufacture of all the azo dyestuffs. The entering azo group goes into the p-position of the benzene ring if this is free, otherwise it takes up the o-position, e.g. diazotized aniline coupled with phenol gives benzeneazophenol. When only half a molecular proportion of nitrous acid is used in the diazotization of an aromatic amine a diazo-amino compound is formed. 

The o- and p-isomers are manufactured by the direct chlorination of benzene in the presence of iron as a catalyst, the resulting mixture being separated by fractional distillation. The w-isomer may be obtained by isomerization of the 0- or p-compound in the presence of a catalyst. 

CH3CH(0H)C(0)0Et. A colourless liquid with a pleasant odour, b.p. 154 C. Manufactured by distilling a mixture of ( )-lactic acid, ethanol and benzene in the presence of a little sulphuric or benzenesulphonic acid. It is a solvent for cellulose nitrate and acetate and also for various resins. Used as a lacquer solvent. 

It is manufactured by reacting benzene with a mixture of nitric and sulphuric acids. Most of the nitrobenzene produced is used to manufacture aniline, which is obtained by reduction. A considerable proportion is used as a raw material in the dyestufTs industry, either as nitrobenzene as such, or as aniline. 

Styrene is manufactured by alkylating benzene with ethene followed by dehydrogenation, or from petroleum reformate coproduction with propylene oxide. Styrene is used almost exclusively for the manufacture of polymers, of which the most important are polystyrene, ABS plastics and styrene-butadiene rubber. U.S. production 1980 3 megatonnes. 

Speed manufacturers need only look at the molecules and imagine them without those extra OHs or methylenedioxy ring structures attached to the benzene core. These particular pathways are, however, more uniquely suited for X precursor production because they take advantage of the hindrance that methylenedioxy ring structures and OHs provide on one side of the benzene core. This helps to better assure that mono chloromethylations or bro-minations will occur whereas di- and tri-substitutions are possible on a naked benzene molecule which speed chemists are going to be using (please don t ask). 

The EB present in recovered mixed xylenes is largely converted to xylenes or benzene. The EB used to make styrene is predominately manufactured by the alkylation of benzene with ethylene. 

Cyclohexane, produced from the partial hydrogenation of benzene [71-43-2] also can be used as the feedstock for A manufacture. Such a process involves selective hydrogenation of benzene to cyclohexene, separation of the cyclohexene from unreacted benzene and cyclohexane (produced from over-hydrogenation of the benzene), and hydration of the cyclohexane to A. Asahi has obtained numerous patents on such a process and is in the process of commercialization (85,86). Indicated reaction conditions for the partial hydrogenation are 100—200°C and 1—10 kPa (0.1—1.5 psi) with a Ru or zinc-promoted Ru catalyst (87—90). The hydration reaction uses zeotites as catalyst in a two-phase system. Cyclohexene diffuses into an aqueous phase containing the zeotites and there is hydrated to A. The A then is extracted back into the organic phase. Reaction temperature is 90—150°C and reactor residence time is 30 min (91—94). 

Manufacture. One commercial process features a three-stage saturation—rearomatization technique using benzene and fluorine gas as raw materials (73). Principal problems with this method are the complex nature of the process, its dependence on fluorine gas which is cosdy to produce, and the poor overall utilization of fluorine, because nearly one-half of the input fluorine is removed during the process. 

Friedel-Crafts alkylation using alkenes has important industrial appHcations. The ethylation of benzene with ethylene to ethylbenzene used in the manufacture of styrene, is one of the largest scale industrial processes. The reaction is done under the catalysis of AlCl in the presence of a proton source, ie, H2O, HCl, etc, although other catalysts have also gained significance. 

Propylation of benzene with propylene, catalyzed by supported phosphoric acid (or related catalysts such as AlCl ), gives cumene [98-82-8] in another important industrial process. Cumene (qv), through the intermediacy of cumene hydroperoxide, is used in the manufacture of phenol (qv). Resorcinol similarly can be made from y -diisopropylbenzene (6). 

Cyclic Hydrocarbons. The cyclic hydrocarbon intermediates are derived principally from petroleum and natural gas, though small amounts are derived from coal. Most cycHc intermediates are used in the manufacture of more advanced synthetic organic chemicals and finished products such as dyes, medicinal chemicals, elastomers, pesticides, and plastics and resins. Table 6 details the production and sales of cycHc intermediates in 1991. Benzene (qv) is the largest volume aromatic compound used in the chemical industry. It is extracted from catalytic reformates in refineries, and is produced by the dealkylation of toluene (qv) (see also BTX Processing). 

Other than fuel, the largest volume appHcation for hexane is in extraction of oil from seeds, eg, soybeans, cottonseed, safflower seed, peanuts, rapeseed, etc. Hexane has been found ideal for these appHcations because of its high solvency for oil, low boiling point, and low cost. Its narrow boiling range minimises losses, and its low benzene content minimises toxicity. These same properties also make hexane a desirable solvent and reaction medium in the manufacture of polyolefins, synthetic mbbers, and some pharmaceuticals. The solvent serves as catalyst carrier and, in some systems, assists in molecular weight regulation by precipitation of the polymer as it reaches a certain molecular size. However, most solution polymerization processes are fairly old it is likely that those processes will be replaced by more efficient nonsolvent processes in time. 

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