Caustic fusion

Caulks Caustic Caustic baryta Caustic extraction Caustic fusion Caustic magnesia Caustic potash Caustic soda... 

Decomposition of Zircon. Zircon sand is inert and refractory. Therefore the first extractive step is to convert the zirconium and hafnium portions into active forms amenable to the subsequent processing scheme. For the production of hafnium, this is done in the United States by carbochlorination as shown in Figure 1. In the Ukraine, fluorosiUcate fusion is used. Caustic fusion is the usual starting procedure for the production of aqueous zirconium chemicals, which usually does not involve hafnium separation. Other methods of decomposing zircon such as plasma dissociation or lime fusions are used for production of some grades of zirconium oxide. 

Sulfonation. Sulfonation of naphthalene with sulfuric acid produces mono-, di-, tri-, and tetranaphthalenesulfonic acids (see Naphthalene derivatives), ah of the naphthalenesulfonic acids form salts with most bases. Naphthalenesulfonic acids are important starting materials in the manufacture of organic dyes (15) (see Azo dyes). They also are intermediates used in reactions, eg, caustic fusion to yield naphthols, nitration to yield nitronaphthalenesulfonic acids, etc. 

Naphthalenesulfonic acids are important chemical precursors for dye intermediates, wetting agents and dispersants, naphthols, and air-entrainment agents for concrete. The production of many intermediates used for making a2o, a2oic, and triphenylmethane dyes (qv) involves naphthalene sulfonation and one or more unit operations, eg, caustic fusion, nitration, reduction, or amination. 

Naphthalenesulfonic Acid. The sulfonation of naphthalene with excess 96 wt % sulfuric acid at < 80°C gives > 85 wt % 1-naphthalenesulfonic acid (a-acid) the balance is mainly the 2-isomer (P-acid). An older German commercial process is based on the reaction of naphthalene with 96 wt % sulfuric acid at 20—50°C (13). The product can be used unpurifted to make dyestuff intermediates by nitration or can be sulfonated further. The sodium salt of 1-naphthalenesulfonic acid is required, for example, for the conversion of 1-naphthalenol (1-naphthol) by caustic fusion. In this case, the excess sulfuric acid first is separated by the addition of lime and is filtered to remove the insoluble calcium sulfate the filtrate is treated with sodium carbonate to precipitate calcium carbonate and leave the sodium l-naphthalenesulfonate/7J(9-/4-J7 in solution. The dry salt then is recovered, typically, by spray-drying the solution. 

In the manufacture of 2-naphthalenol, 2-naphthalenesulfonic acid must be converted to its sodium salt this can be done by adding sodium chloride to the acid, and by neutralizing with aqueous sodium hydroxide or neutralizing with the sodium sulfite by-product obtained in the caustic fusion of the sulfonate. The cmde sulfonation product, without isolation or purification of 2-naphthalenesulfonic acid, is used to make 1,6-, 2,6-, and 2,7-naphthalenedisulfonic acids and 1,3,6-naphthalenetrisulfonic acid by further sulfonation. By nitration, 5- and 8-nitro-2-naphthalenesulfonic acids, [89-69-1] and [117-41-9] respectively, are obtained, which are intermediates for Cleve s acid. All are dye intermediates. The cmde sulfonation product can be condensed with formaldehyde or alcohols or olefins to make valuable wetting, dispersing, and tanning agents. 

Acid-cataly2ed hydroxylation of naphthalene with 90% hydrogen peroxide gives either 1-naphthol or 2-naphthiol at a 98% yield, depending on the acidity of the system and the solvent used. In anhydrous hydrogen fluoride or 70% HF—30% pyridine solution at — 10 to + 20°C, 1-naphthol is the product formed in > 98% selectivity. In contrast, 2-naphthol is obtained in hydroxylation in super acid (HF—BF, HF—SbF, HF—TaF, FSO H—SbF ) solution at — 60 to — 78°C in > 98% selectivity (57). Of the three commercial methods of manufacture, the pressure hydrolysis of 1-naphthaleneamine with aqueous sulfuric acid at 180°C has been abandoned, at least in the United States. The caustic fusion of sodium 1-naphthalenesulfonate with 50 wt % aqueous sodium hydroxide at ca 290°C followed by the neutralization gives 1-naphthalenol in a ca 90% yield. 

Methylphenol. T -Cresol is produced synthetically from toluene. Toluene is sulfonated to yield T i ra-toluenesulfonic acid, which is then converted to 4-methylphenol via the caustic fusion route. A minor amount of 4-methylphenol is also derived from petroleum cmde and coal tars. 4-Methylphenol [106-44-5] is available in 55-gal dmms (208-L) and in bulk quantities as a molten material. 

Solvent Extraction. The industrial separation of tantalum from niobium was carried out historicahy by the Marignac process of fractional crystallization of potassium heptafluorotantalate and potassium heptafluoroniobate (15,16) or the long-estabhshed Fansteel process (17), which involved the decomposition of the ore by a caustic fusion procedure. Processors have replaced these expensive processes by procedures based on solvent extraction. This technique was developed in the United States at Ames Laboratory and the U.S. Bureau of Mines (18). Figure 2 shows the flow sheet of an industrial instahation for the hydrometahurgical processing of tantalum—niobium raw materials. 

Oxide Chlorides. Zirconium oxide dichloride, ZrOCl2 -8H2 0 [13520-92-8] commonly called zirconium oxychloride, is really a hydroxyl chloride, [Zr4(OH)g T6H2 0]Clg T2H2O (189). Zirconium oxychloride is produced commercially by caustic fusion of zircon, followed by water washing to remove sodium siUcate and to hydrolyze the sodium zirconate the wet filter pulp is dissolved in hot hydrochloric acid, and ZrOCl2 -8H2 O is recovered from the solution by crystallization. An aqueous solution is also produced by the dissolution and hydrolysis of zirconium tetrachloride in water, or by the addition of hydrochloric acid to zirconium carbonate. 

H-C-H H-C-H H-C-H Caustic fusion NaOH Sebacic acid, capryl alcohol... 

Chemical leaching (1,12) with acids is used to extract metal contamination. High purity zirconia, Zr02, is produced by the caustic fusion of zircon [14475-73-1], ZrSiO, foUowed by the chemical removal of sUica. Chemical leaching is generaUy foUowed by washing. 

Fusion/Hydroxylation. The conversion of arylsulfonic acids to the corresponding hydroxy compound is normally effected by heating with caustic soda (caustic fusion). The primary examples are P-naphthol in the naphthalene series and resorcinol in the benzene series further examples are m- am in oph en o1 from metanilic acid and diethyl-y -arninophenol from /V,/V-diethy1metani1ic acid. In the naphthalene series the hydroxy group is much... 

This process was not acceptable for several reasons low yields, poor quaUty, and the high cost of bromine. Later, at BASF, a process was developed for the manufacture of ali2artn by the caustic fusion of anthraquinone-2-sulfonic acid (so-called silver salt) which was made by sulfonating anthraquinone with sulfuric acid. This process was patented in England on the 25th of June, 1869. One day later, W. Perkin appHed for a patent for the manufacture of ali2ariQ by a process almost identical to the German process except that the "silver salt" was prepared as follows ... 

Gray iron is resistant to concentrated acids (nitric, sulfuric, phosphoric) as well as to some alkahne and caustic solutions. Caustic fusion pots are usually made from gray cast iron with low silicon content cast-iron valves, pumps, and piping are common in sulfuric acid plants. 

Previously, phenol was produced from benzene by sulfonation followed by caustic fusion to sodium phenate. Phenol is released from the sodium salt of phenol by the action of carbon dioxide or sulfur dioxide. 

Stirrer, for caustic fusion, 30, 104, 105 seal for, 30, 54 Stobbe condensation, 30, 18 Styrene, 33, 72 Styrene dibromide, 30, 73 Styrene oxide, 31, 3 Succinic acid, cc-benzhydrylidene-,... 

Caustic coupling process, 10 356-357 Caustic flooding, 15 629-630 Caustic fusion, of zircon, 26 628 Causticiation, 15 63 in Bayer process, 2 352 slaked lime in, 15 45, 63 Caustic scrubbing, phosgene decomposition by, 15 807... 

The classic caustic fusion of sulfonic acid salts has been used for preparing 2,6-dinaphthol and its derivatives. Other more recent procedures have employed the direct hydrolysis of aryl bromides and the oxidation of aryl Grignard reagents. ... 

Holmium is obtained from monazite, bastnasite and other rare-earth minerals as a by-product during recovery of dysprosium, thulium and other rare-earth metals. The recovery steps in production of all lanthanide elements are very similar. These involve breaking up ores by treatment with hot concentrated sulfuric acid or by caustic fusion separation of rare-earths by ion-exchange processes conversion to halide salts and reduction of the hahde(s) to metal (See Dysprosium, Gadolinium and Erbium). 

Sodium sulfate also is obtained as a byproduct of manufacturing phenol by caustic fusion. 

Insoluble silica residues are removed by filtration. The solution now contains beryllium, iron, yttrium, and the rare earths. The solution is treated with oxalic acid to precipitate yttrium and the rare earths. The precipitate is calcined at 800°C to form rare earth oxides. The oxide mixture is dissolved in an acid from which yttrium and the rare earths are separated by the ion-exchange as above. Caustic fusion may be carried out instead of acid digestion to open the ore. Under this condition sihca converts to sodium sihcate and is leached with water. The insoluble residue containing rare earths and yttrium is dissolved in an acid. The acid solution is fed to an ion exchange system for separating thuhum from other rare earths. 

Perhaps the most significant benzopyridine fungicides are the normal metal chelate compounds derived from 8-hydroxyquinoline (33), itself manufactured from quinoline by sulfonation/caustic fusion. Applications of (33) have been reviewed (56CRV217). Related compounds include quinacetol sulfate (34) (B-77MI20901) and halacrinate (35) (B-77MI20901). 

Vanillic acid has been prepared from vanillin in small amounts by action of moist air, exposure to sunlight and nitrobenzene, reaction with soil bacleria," ozone, and by caustic fusion. High yields of vanillic acid have been obtained from vanillin by con-... 

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