Processes butane oxidation

World installed capacity for formic acid is around 330,000 t/yr. Around 60% of the production is based on methyl formate. Of the remainder, about 60% comes from Hquid-phase oxidation and 40% from formate salt-based processes. The largest single producer is BASF, which operates a 100,000 t/yr plant at Ludwigshafen in Germany. The only significant U.S. producer of formic acid is Hoechst-Celanese, which operates a butane oxidation process. 

In the case of the VPO catalyst for the butane oxidation process and the MCM catalyst for the acrylonitrile process, the preferred precursor of the peripheral hard phase is polysilicic acid (PSA). The term "polysilicic acid" is generally reserved for those "silicic acids that have been formed and partially polymerized in the pH range 1-4 and consist of ultimate silica particles generally smaller than 3-4 nm diameter" (4). Small, discrete particles of colloidal silica also migrate to the periphery of the droplet, but they do not coalesce as extensively as PSA in drying. The larger the particle size, the lower the mechanical strength of the coalesced dry product. 

Figure 2a illustrates the improvement in attrition resistance of a VPO catalyst by the addition of only 10% silica as PSA. Both samples of VPO, one with no PSA added and the other with 10% PSA, were tested as catalysts in the butane oxidation process to make maleic anhydride and showed no difference in activity or selectivity. Both fluid bed and recirculating solids reactors were used for the tests of catalytic performance (1) (2). 

The n-butane oxidation process is interesting as it is an extensive oxidation, with the cleaving of eight C—H bonds and the introduction of three oxygen atoms, yet... 

Even though methanol carbonylation is the favored process for new acetic acid capacity today, existing paraffin oxidation plants remain quite competitive where coproducts can be marketed successfully [2, 3]. Over half the original capacity of acetic acid plants based on paraffin oxidation remains in use today. In North America, Hoechst Celanese operates two facilities using the butane oxidation process to make acetic acid. The reported 1994 capacity at Pampa, Texas, is 250000 metric tons/year, while that at monton, Alberta, is 75 000 metric tons/year [4]. There are two plants believed to be using the naphtha oxidation process to make acetic acid BP Chemicals in Hull, England, with a capacity of 210000 metric tons/year [5] and a state complex in Armenia (in the former USSR) with a capacity reported to be 35 000 metric tons/year [6]. 

The significant reductions in acetic acid capacity based on paraffin oxidation that have occurred include those at (1) the butane oxidation plant operated by Union Carbide at Brownsville, Texas, (2) butane oxidation processes in the Netherlands and Germany, and (3) a Russian naphtha oxidation plant. 

Among the companies which participated in developing a process starting with n-butane are Amoco, Chevron, Mobil Oil Petrotex and Standard OiL Moreover Badger, on the one hand, and Lummus/A lusuisse Italia, Standard Oil and UCB on the other, are currently developing fluidized bed n-butane oxidation processes. 

A major advantage of the riser reactor for catalytic cracking is that the gas and solid move in nearly plug flow, which gives more uniform catalytic activity and better selectivity than with a bubbling or turbulent fluidized bed. A riser reactor can be used for other rapid catalytic reactions, such as the production of acrolein from propylene [3] or the partial oxidation of n-butane to make maleic anhydride. In DuPont s butane oxidation process... 

The rates of formation and the rates of oxidation of acetaldehyde at different stages of butane oxidation process have also been studied by introducing at different reaction times —AcOH and measuring its specific activity vs reaction time by Neiman s... 

Patience GS, Bockrath RE Butane oxidation process development in a circulating fluidized bed, Appl Catal, A 376 4—12, 2010. http //dx.doi.Org/10.1016/j.apcata.2009.10.023. 

Historically, formaldehyde has been and continues to be manufactured from methanol. EoUowing World War II, however, as much as 20% of the formaldehyde produced in the United States was made by the vapor-phase, noncatalytic oxidation of propane and butanes (72). This nonselective oxidation process produces a broad spectmm of coproducts (73) which requites a complex cosdy separation system (74). Hence, the methanol process is preferred. The methanol raw material is normally produced from synthesis gas that is produced from methane. 

Butane-Based Fixed-Bed Process Technology. Maleic anhydride is produced by reaction of butane with oxygen using the vanadium phosphoms oxide heterogeneous catalyst discussed earlier. The butane oxidation reaction to produce maleic anhydride is very exothermic. The main reaction by-products are carbon monoxide and carbon dioxide. Stoichiometries and heats of reaction for the three principal reactions are as follows ... 

This process may be competitive with butane oxidation (see Hydrocarbon oxidation) which produces a spectmm of products (138), but neither process is competitive with the process from synthesis gas practiced by Monsanto (139) and BASF (140) which have been used in 90% of the new acetic acid capacity added since 1975. 

Like propane, n-hutane is mainly obtained from natural gas liquids. It is also a hy-product from different refinery operations. Currently, the major use of n-hutane is to control the vapor pressure of product gasoline. Due to new regulations restricting the vapor pressure of gasolines, this use is expected to he substantially reduced. Surplus n-butane could be isomerized to isobutane, which is currently in high demand for producing isobutene. Isobutene is a precursor for methyl and ethyl tertiary butyl ethers, which are important octane number boosters. Another alternative outlet for surplus n-butane is its oxidation to maleic anhydride. Almost all new maleic anhydride processes are based on butane oxidation. 

For many years the catalytic air oxidation of benzene was the main source of maleic anhydride. Obviously, two carbons from each ring are wasted as carbon dioxide in this process. Although some is still made that way, most modem maleic anhydride plants are based on butane oxidation. Because butane is forecast to be plentiful and low-cost, new routes to four-carbon chemicals from maleic anhydride are under active development. 

The industrial catalyst for n-butane oxidation to maleic anhydride (MA) is a vanadium/phosphoras mixed oxide, in which bulk vanadyl pyrophosphate (VPP) (VO)2P207 is the main component. The nature of the active surface in VPP has been studied by several authors, often with the use of in situ techniques (1-3). While in all cases bulk VPP is assumed to constitute the core of the active phase, the different hypotheses concern the nature of the first atomic layers that are in direct contact with the gas phase. Either the development of surface amorphous layers, which play a direct role in the reaction, is invoked (4), or the participation of specific planes contributing to the reaction pattern is assumed (2,5), the redox process occurring reversibly between VPP and VOPO4. 

The selective oxidation of ra-butane to give maleic anhydride (MA) catalyzed by vanadium phosphorus oxides is an important commercial process (99). MA is subsequently used in catalytic processes to make tetrahydrofurans and agricultural chemicals. The active phase in the selective butane oxidation catalyst is identified as vanadyl pyrophosphate, (V0)2P207, referred to as VPO. The three-dimensional structure of orthorhombic VPO, consisting of vanadyl octahedra and phosphate tetrahedra, is shown in Fig. 17, with a= 1.6594 nm, b = 0.776 nm, and c = 0.958 nm (100), with (010) as the active plane (99). Conventional crystallographic notations of round brackets (), and triangular point brackets (), are used to denote a crystal plane and crystallographic directions in the VPO structure, respectively. The latter refers to symmetrically equivalent directions present in a crystal. 

Other methods for the preparation of acetic acid are partial oxidation of butane, oxidation of ethanal -obtained from Wacker oxidation of ethene-, biooxidation of ethanol for food applications, and we may add the same carbonylation reaction carried out with a cobalt catalyst or an iridium catalyst. The rhodium and iridium catalysts have several distinct advantages over the cobalt catalyst they are much fester and fer more selective. In process terms the higher rate is translated into much lower pressures (the cobalt catalyst is operated by BASF at pressures of 700 bar). For years now the Monsanto process (now owned by BP) has been the most attractive route for the preparation of acetic acid, but in recent years the iridium-based CATTVA process, developed by BP, has come on stream. 

In Asia, Asahl and Mitsubishi have commercialized a process using isobutylene or tertiary butyl alcohol to malce methacrolein. Then they further oxidize it to methacryiic acid, MAA, which is then esterified with methanol to MMA. The same process might eventually start with iso butane oxidation to bypass the olefin step. 

A wide variety of compositions and materials of slightly different crystal properties were prepared for evaluation as butane oxidation catalysts. These materials were active for butane oxidation, and the activity and selectivity varied according to the process parameters used for synthesis. This chemical performance data will be reported separately. 

The EM studies show that the novel glide shear mechanism in the solid state heterogeneous catalytic process preserves active acid sites, accommodates non-stoichiometry without collapsing the catalyst bulk structure and allows oxide catalysts to continue to operate in selective oxidation reactions (Gai 1997, Gai et al 1995). This understanding of which defects make catalysts function may lead to the development of novel catalysts. Thus electron microscopy of VPO catalysts has provided new insights into the reaction mechanism of the butane oxidation catalysis, catalyst aging and regeneration. 

Direct Oxidation. Direct oxidation of petroleum hydrocarbons has been practiced on a small scale since 1926 methanol, formaldehyde, and acetaldehyde are produced. A much larger project (29) began operating in 1945. The main product of the latter operation is acetic acid, used for the manufacture of cellulose acetate rayon. The oxidation process consists of mixing air with a butane-propane mixture and passing the compressed mixture over a catalyst in a tubular reaction furnace. The product mixture includes acetaldehyde, formaldehyde, acetone, propyl and butyl alcohols, methyl ethyl ketone, and propylene oxide and glycols. The acetaldehyde is oxidized to acetic acid in a separate plant. Thus the products of this operation are the same as those (or their derivatives) produced by olefin hydration and other aliphatic syntheses. 

The synthesis of intermediates and monomers from alkanes by means of oxidative processes, in part replacing alkenes and aromatics as the traditional building blocks for the chemical industry [2]. Besides the well-known oxidation of n-butane to maleic anhydride, examples of processes implemented at the industrial level are (i) the direct oxidation of ethane to acetic acid, developed by Sabic (ii) the ammoxidation of propane to acrylonitrile, developed by INEOS (former BP) and by Mitsubishi, and recently announced by Asahi to soon become commercial (iii) the partial oxidation of methane to syngas (a demonstration unit is being built by ENI). Many other reactions are currently being investigated, for example, (i) the... 

A New Process for n-Butane Oxidation to Maleic Anhydride Using a Circulating Fluidized Bed Reactor. In Circulating Fluidized Bed Technology TV. Ed. A. A. Avidan. New York AlChE Publications. 

Acetic acid is manufactured by three processes acetaldehyde oxidation, //-butane oxidation, and methanol carbonylation.Ethylene is the exclusive organic raw material for making acetaldehyde, 70 percent of which is further oxidized to acetic acid or acetic anhydride. The single-stage (Wacker) process for making acetaldehyde involves cupric chloride and a small amount of palladium chloride in aqueous solution as a catalyst. 

Small amounts of synthetic alcohol occur as by-products in various chemical processes, particularly production of acetic acid via butane oxidation. One company is producing about 12 million gallons of by-product ethanol at present but is not recovering it. 3... 

As described above, butylene is employed as part of the feedstock in maleic anhydride synthesis (Table 3, entry 27). Process conditions are similar but, because of the pricing of feedstocks, butane oxidation is mainly employed. 

This section shows, for four examples of increasing complexity, how precipitates are formed and how the properties of the precipitates are controlled to produce a material suitable for catalytic applications. The first two examples comprise silica, which is primarily used as support material and is usually formed as an amorphous solid, and alumina, which is also used as a catalytically active material, and which can be formed in various modifications with widely varying properties as pure precipitated compounds. The other examples are the results of coprecipitation processes, namely Ni/ AI2O3 which can be prepared by several pathways and for which the precipitation of a certain phase determines the reduction behavior and the later catalytic properties, and the precipitation of (VOjHPCU 0.5 H2O which is the precursor of the V/P/O catalyst for butane oxidation to maleic anhydride, where even the formation of a specific crystallographic face with high catalytic activity has to be controlled. 

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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