Removal catalysts

The nitro alcohols available in commercial quantities are manufactured by the condensation of nitroparaffins with formaldehyde [50-00-0]. These condensations are equiUbrium reactions, and potential exists for the formation of polymeric materials. Therefore, reaction conditions, eg, reaction time, temperature, mole ratio of the reactants, catalyst level, and catalyst removal, must be carefully controlled in order to obtain the desired nitro alcohol in good yield (6). Paraformaldehyde can be used in place of aqueous formaldehyde. A wide variety of basic catalysts, including amines, quaternary ammonium hydroxides, and inorganic hydroxides and carbonates, can be used. After completion of the reaction, the reaction mixture must be made acidic, either by addition of mineral acid or by removal of base by an ion-exchange resin in order to prevent reversal of the reaction during the isolation of the nitro alcohol (see Ion exchange). 

Similar to IFP s Dimersol process, the Alphabutol process uses a Ziegler-Natta type soluble catalyst based on a titanium complex, with triethyl aluminum as a co-catalyst. This soluble catalyst system avoids the isomerization of 1-butene to 2-butene and thus eliminates the need for removing the isomers from the 1-butene. The process is composed of four sections reaction, co-catalyst injection, catalyst removal, and distillation. Reaction takes place at 50—55°C and 2.4—2.8 MPa (350—400 psig) for 5—6 h. The catalyst is continuously fed to the reactor ethylene conversion is about 80—85% per pass with a selectivity to 1-butene of 93%. The catalyst is removed by vaporizing Hquid withdrawn from the reactor in two steps classical exchanger and thin-film evaporator. The purity of the butene produced with this technology is 99.90%. IFP has Hcensed this technology in areas where there is no local supply of 1-butene from other sources, such as Saudi Arabia and the Far East. 

Chemicals responsible for odor in some PUR foams were synthesised by polymerisation of PO in CH2CI2 with Bp2(C2H )20 catalyst (114). The yield was 25% volatile material and 75% polymeric material. The 25% fraction consisted of dimethyldioxane isomers, dioxolane isomers, DPG, TPG, crown ethers, tetramers, pentamers, etc, and 2-ethy1-4,7-dimethyl-1,3,6-trioxacane (acetal of DPG and propionaldehyde). The latter compound is mainly responsible for the musty odor found in some PUR foams. This material is not formed under basic conditions but probably arises during the workup when acidic clays are used for catalyst removal. 

Modem catalysts produce a much higher percentage of isotactic polypropylene than ia the past, eliminating the need for a cosdy extraction step to remove an atactic fraction. Yields ate high enough (>10,000 g polymer/g catalyst) so that a catalyst removal (de-ashing) step is no longer requited. 

The requisite intermediate, ethyl 4-dimethylaminocyclohexylcarboxylate is prepared as follows 33 g of ethyl p-aminobenzoate dissolved in 300 cc of absolute ethanol containing 16.B cc of concentrated hydrochloric acid is hydrogenated at 50 pounds hydrogen pressure in the presence of 2 g of platinum oxide. The theoretical quantity of hydrogen is absorbed in several hours, the catalyst removed by filtration and the filtrate concentrated to dryness in vacuo. The residue Is dissolved in water, made alkaline with ammonium hydroxide and extracted with chloroform. After removal of the solvent, the residual oil is distilled to yield ethyl 4-aminocyclohexylcarboxylate, boiling point 114°C to 117°C/10 mm. 

The rhodium complexes are excellent catalysts for hydrogenation of NBR. At low temperature and pressure, high catalyst concentrations are used to obtain a better rate of reactions. Due to higher selectivity of the reaction, pressure and temperature can be increased to very high values. Consequently the rhodium concentration can be greatly reduced, which leads to high turnover rates. The only practical drawback of Rh complex is its high cost. This has initiated the development of techniques for catalyst removal and recovery (see Section VU), as well as alternate catalyst systems based on cheaper noble metals, such as ruthenium or palladium (see Sections IV.A and B). 

The second method used to reduce exliaust emissions incorporates postcombustion devices in the form of soot and/or ceramic catalytic converters. Some catalysts currently employ zeolite-based hydrocarbon-trapping materials acting as molecular sieves that can adsorb hydrocarbons at low temperatures and release them at high temperatures, when the catalyst operates with higher efficiency. Advances have been made in soot reduction through adoption of soot filters that chemically convert CO and unburned hydrocarbons into harmless CO, and water vapor, while trapping carbon particles in their ceramic honeycomb walls. Both soot filters and diesel catalysts remove more than 80 percent of carbon particulates from the exliatist, and reduce by more than 90 percent emissions of CO and hydrocarbons. 

The Alphabutol process (Figure 7-8) operates at low temperatures (50-55°C) and relatively low pressures (22-27 atm). The reaction occurs in the liquid phase without a solvent. The process scheme includes four sections the reactor, the co-catalyst injection, catalyst removal, and distillation. The continuous co-catalyst injection of an organo-hasic compound deactivates the catalyst downstream of the reactor withdrawal valve to limit isomerization of 1-hutene to 2-hutene. Table 7-2 shows the feed and product quality from the dimerization process. 

Catalysts developed in the titanium-aluminum alkyl family are highly reactive and stereoselective. Very small amounts of the catalyst are needed to achieve polymerization (one gram catalyst/300,000 grams polymer). Consequently, the catalyst entrained in the polymer is very small, and the catalyst removal step is eliminated in many new processes. Amoco has introduced a new gas-phase process called absolute gas-phase in which polymerization of olefins (ethylene, propylene) occurs in the total absence of inert solvents such as liquefied propylene in the reactor. Titanium residues resulting from the catalyst are less than 1 ppm, and aluminum residues are less than those from previous catalysts used in this application. 

An issue with ATRP is the residual metal catalyst and its removal from the polymer post-polymerization, Many papers have been written on catalyst removal and recycling.309... 

Supported copper catalysts have also been described/29 340 The main impetus for the development of supported ATRP catalysts has been to facilitate catalyst removal and, in some cases, to allow for catalyst recycling. 

Experiments showed that high methyl ester yields can be achieved with solid bases and super acids under moderate reaction conditions. The solid bases were more effective catalysts than the solid super acids. High stability can be achieved by an ordinary inexpensive preparation process, and the catalyst can be separated easily from the reaction products in the heterogeneous catalysis process. The costly catalyst removal process can be avoided compared with the homogeneous process. Therefore, the heterogeneous process using a solid catalyst should be more economical for biodiesel production. 

Figure 5.2 Environmental scores of reduction steps in routes B and C (Scheme 5.1) according to the Eco-lndicator95 evaluation method (Figure 2 in reference [11 ]). Ml = catalyst, M2 = reduction, M3 = catalyst removal, M4 = extraction, M5 = solvent drain off, M5 = rectification, M7 = enantiomeric purification, M8 = solvent recycling. Reproduced from Jodicke [11 ], Copyright 1 999, with permission from Elsevier.

Rather than selective non-catalytic reduction, the reduction can be carried out over a catalyst (e.g. zeolite) at 150 to 450 C. This is known as selective catalytic reduction. Figure 25.31 shows a typical selective catalytic reduction arrangement10. Either anhydrous or aqueous ammonia can be used. This is mixed with air and injected into the flue gas stream upstream of the catalyst. Removal efficiency of up to 95% is possible. Again, slippage of excess ammonia needs to be controlled. 

CP [Continuous polymerization] A continuous process for making high-density polyethylene, based on the Ziegler process but using a much more active catalyst so that de-ashing (catalyst removal) is not required. Developed by Mitsui Petrochemical Industries and upgraded into its CX process, which was first licensed in 1976. 

Adsorption is commonly used for catalyst removal/recovery. The process involves treating the polymer solution with suitable materials which adsorb the catalyst residue and are then removed by filtration. Panster et al. [105] proposed a method involving adsorbers made from organosiloxane copolycondensates to recover rhodium and ruthenium catalysts from solutions of HNBR. These authors claimed that the residual rhodium could be reduced to less than 5 ppm, based on the HNBR content which had a hydrogenation conversion of over... 

C. Usually the polymerisation is carried out in the presence of Ziegler-Natta catalysts based on titanium tetrachloride and aluminium alkyl. The catalyst may be either prepared or formed in the reactor. Usually, the polymerisation is carried out in presence of a hydrocarbon solvent. The polymer is insoluble in the solvent. The reaction is terminated by addition of an alcohol and catalyst extracted with alcoholic hydrochloric acid. Catalyst removal is important for electrical insolution used. The Polymer chain obtained by this process is essentially linear. 

Catalyst removal is important for electrical insulation uses. The Polymer chain obtained by this process is essentially linear. 

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