Catalyst processes

Rhodium Ca.ta.lysts. Rhodium carbonyl catalysts for olefin hydroformylation are more active than cobalt carbonyls and can be appHed at lower temperatures and pressures (14). Rhodium hydrocarbonyl [75506-18-2] HRh(CO)4, results in lower -butyraldehyde [123-72-8] to isobutyraldehyde [78-84-2] ratios from propylene [115-07-17, C H, than does cobalt hydrocarbonyl, ie, 50/50 vs 80/20. Ligand-modified rhodium catalysts, HRh(CO)2L2 or HRh(CO)L2, afford /iso-ratios as high as 92/8 the ligand is generally a tertiary phosphine. The rhodium catalyst process was developed joindy by Union Carbide Chemicals, Johnson-Matthey, and Davy Powergas and has been Hcensed to several companies. It is particulady suited to propylene conversion to -butyraldehyde for 2-ethylhexanol production in that by-product isobutyraldehyde is minimized. 

Most cellulose acetate is manufactured by a solution process, ie, the cellulose acetate dissolves as it is produced. The cellulose is acetylated with acetic anhydride acetic acid is the solvent and sulfuric acid the catalyst. The latter can be present at 10—15 wt % based on cellulose (high catalyst process) or at ca 7 wt % (low catalyst process). In the second most common process, the solvent process, methylene chloride replaces the acetic acid as solvent, and perchloric acid is frequentiy the catalyst. There is also a seldom used heterogeneous process that employs an organic solvent as the medium, and the cellulose acetate produced never dissolves. More detailed information on these processes can be found in Reference 28. 

Silver Catalyst Process. In early formaldehyde plants methanol was oxidized over a copper catalyst, but this has been almost completely replaced with silver (75). The silver-catalyzed reactions occur at essentially atmospheric pressure and 600 to 650°C (76) and can be represented by two simultaneous reactions ... 

Eig. 1. Flow scheme of a typical silver catalyst process. S = steam CW = cooling water. 

The requirements for the material of constmction are the same as for the silver catalyst process except the use of alloys to protect the catalyst is not as important. 

The quahty of naphthalene required for phthaUc anhydride manufacture is generally 95% minimum purity. The fixed plants do not require the high (>98%) purity naphthalene product and low (<50 ppm) sulfur. The typical commercial coal-tar naphthalene having a purity ca 95% (freezing point, 77.5°C), a sulfur content of ca 0.5%, and other miscellaneous impurities, is acceptable feedstock for the fixed-bed catalyst process based on naphthalene. 

Nonregenerable aluminum chloride catalyst is employed with various carriers ia a fixed-bed or Hquid contactor. Platinum or other metal catalyst processes that utilize fixed-bed operation can be either regenerable or nonregenerable. The reaction conditions vary widely, between 40—480°C and 1035— 6900 kPa (150—1000 psi), depending on the particular process and feedstock. 

SPA Catalyst. The sohd phosphoric acid (SPA) catalyst process has been the domiaant source of cumene siace the 1930s. This process accounts for more than 90% of cumene operating capacity (59). A simplified process flow diagram is given ia Figure 5. 

Propylene feed, fresh benzene feed, and recycle benzene are charged to the upflow reactor, which operates at 3—4 MPa (400—600 psig) and at 200—260°C. The SPA catalyst provides an essentially complete conversion of propylene [115-07-1] on a one-pass basis. A typical reactor effluent yield contains 94.8 wt % cumene and 3.1 wt % diisopropylbenzene [25321-09-9] (DIPB). The remaining 2.1% is primarily heavy aromatics. This high yield of cumene is achieved without transalkylation of DIPB and is unique to the SPA catalyst process. 

Soon after the first successful diamond synthesis by the solvent—catalyst process, a pilot plant for producing synthetic diamond was estabUshed, the efficiency of the operation was increased, production costs declined, and product performance was improved while the uses of diamond were extended. Today the price of synthesized diamond is competitive with that of natural diamonds. 

CSM products may be divided into three groups depending on the type of precursor resin low density (LDPE), high density (HDPE), and linear low density (LLDPE). LDPE is made by a high pressure free-radical process, while HDPE and LLDPE are made via low pressure, metal coordination catalyst processes (12) (see Olefin polymers). 

Alkylation. Ethylbenzene [100-41 -4] the precursor of styrene, is produced from benzene and ethylene. The ethylation of benzene is conducted either ia the Hquid phase ia the preseace of a Eriedel-Crafts catalyst (AlCl, BE, EeCl ) or ia the vapor phase with a suitable catalyst. The Moasanto/Lummus process uses an aluminum chloride catalyst that yields more than 99% ethylbenzene (13). More recently, Lummus and Union Oil commercialized a zeoHte catalyst process for Hquid-phase alkylation (14). Badger and Mobil also have a vapor-phase alkylation process usiag zeoHte catalysts (15). Almost all ethylbenzene produced is used for the manufacture of styrene [100-42-5] which is obtained by dehydrogenation ia the preseace of a suitable catalyst at 550—640°C and relatively low pressure, <0.1 MPa (<1 atm). 

Sohd Catalysts Processes with solid catalysts are affected by diffusion of heat and mass (1) within the pores of the pellet, (2) between the fluid and the particle, and (3) axially and radially within the packed bed. Criteria in terms of various dimensionless groups have been developed to tell when these effects are appreciable. They are discussed by Mears (Ind. Eng. Chem. Proc. Des. Devel., 10, 541-547 [1971] Jnd. Eng. Chem. Fund., 15, 20-23 [1976]) and Satterfield (Heterogeneous Cataly.sls in Practice, McGraw-Hill, 1991, p. 491). 

While there are hydroformers still operating, reforming today is generally carried out in fixed bed units using platinum catalysts, because of their superior product yield and distribution. Fluid platinum catalyst processes are not feasible because catalyst losses would be too great. 

The FCC process has a long history of innovation and will continue to play a key role in the overall success of the refining industry. The continuing developments will primarily be in the areas of catalyst, process, and hardware technologies. 

Olefin Polymerization Catalyst Process for its Preparation and Use , US Patent 5578537, to Hoechst, 1996. 

A CSTR with slurried catalyst processes a reaction with rate equation... 

Feb Competition and Business Strategy Product Design (1) Indoor air survey (2) Prototype Chemical Design and Processing (1) Adsorbents (2) Catalysts. Process Safety Analysis Process Control and Instrumentation Environmental Impact Assessemsnt Report Writing... 

The tendency in the past decades has been to replace them with solid acids (Figure 13.1). These solid acids could present important advantages, decreasing reactor and plant corrosion problems (with simpler and safer maintenance), and favoring catalyst regeneration and environmentally safe disposal. This is the case of the use of zeolites, amorphous sihco-aluminas, or more recently, the so-called superacid solids, that is, sulfated metal oxides, heteropolyoxometalates, or nation (Figure 13.1). It is clear that the well-known carbocation chemistry that occurs in liquid-acid processes also occurs on the sohd-acid catalysts (similar mechanisms have been proposed in both catalyst types) and the same process variables that control liquid-acid reactions also affect the solid catalyst processes. 

Mitsubishi Electric Corporation investigated alloyed catalysts, processes to produce thinner electrolytes, and increases in utilization of the catalyst layer (20). These improvements resulted in an initial atmospheric performance of 0.65 mV at 300 mA/cm or 0.195 W/cm, which is higher than the IFC performance mentioned above (presented in Table 5-2 for comparison). Note that this performance was obtained on small 100 cm cells and may not yet have been demonstrated with full-scale cells in stacks. Approaches to increase life are to use series fuel gas flow in the stack to alleviate corrosion, provide well-balanced micro-pore size reservoirs to avoid electrolyte flooding, and use a high corrosion resistant carbon support for the cathode catalyst. These improvements have resulted in the lowest PAFC degradation rate publicly acknowledged, 2 mV/1000 hours for 10,000 hours at 200 to 250 mA/cm in a short stack with 3600 cm area cells. 

What are the major differences between a fixed bed catalyst process and a fluidized bed process What are the advantages of a fluidized bed process The disadvantages ... 

In this chapter, the big four thermoplastics are covered polyethylene, polypropylene, polyvinyl chloride, and polystyrene. Like most other thermoplastics, they are long-chain polymers that become soft when heated and can be molded under pressure. They are linear- or branch-chained and, except for some exotic copolymers, have little or no cross-linking. Technological advances continue. Research in copolymerization, catalysts, processing, blending, and fabricating continues even as you read this. 

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