Chlorine production chemical processes

Hydrogen Chloride as By-Product from Chemical Processes. Over 90% of the hydrogen chloride produced in the United States is a by-product from various chemical processes. The cmde HCl generated in these processes is generally contaminated with impurities such as unreacted chlorine, organics, chlorinated organics, and entrained catalyst particles. A wide variety of techniques are employed to treat these HCl streams to obtain either anhydrous HCl or hydrochloric acid. Some of the processes in which HCl is produced as a by-product are the manufacture of chlorofluorohydrocarbons, manufacture of aUphatic and aromatic hydrocarbons, production of high surface area siUca (qv), and the manufacture of phosphoric acid [7664-38-2] and esters of phosphoric acid (see Phosphoric acid and phosphates). 

Potassium Nitrate. Potassium nitrate [7757-79-17, KNO, is produced commercially in the United States based on the reaction of potassium chloride and nitric acid (qv) (35). Ammonia (qv) oxidation is the source for the nitric acid and the reaction is manipulated chemically to yield chlorine as a co-product. The process is operated at an elevated temperature to drive the reaction to completion according to the following equation ... 

Chlorine atoms obtained from the dissociation of chlorine molecules by thermal, photochemical, or chemically initiated processes react with a methane molecule to form hydrogen chloride and a methyl-free radical. The methyl radical reacts with an undissociated chlorine molecule to give methyl chloride and a new chlorine radical necessary to continue the reaction. Other more highly chlorinated products are formed in a similar manner. Chain terrnination may proceed by way of several of the examples cited in equations 6, 7, and 8. The initial radical-producing catalytic process is inhibited by oxygen to an extent that only a few ppm of oxygen can drastically decrease the reaction rate. In some commercial processes, small amounts of air are dehberately added to inhibit chlorination beyond the monochloro stage. 

A newer technology for the manufacture of chromic acid uses ion-exchange (qv) membranes, similar to those used in the production of chlorine and caustic soda from brine (76) (see Alkali and cm ORiNE products Chemicals frombrine Mep rane technology). Sodium dichromate crystals obtained from the carbon dioxide option of Figure 2 are redissolved and sent to the anolyte compartment of the electrolytic ceU. Water is loaded into the catholyte compartment, and the ion-exchange membrane separates the catholyte from the anolyte (see Electrochemical processing). 

Electrochemistry is widely used in industry, for example in effluent treatment, corrosion prevention and electroplating as well as in electrochemical synthesis. Electrochemical synthesis is a well-established technology for major processes such as aluminium and chlorine production there is, however, increased interest in the use of electrochemistry for clean synthesis of fine chemicals. The possible green benefits of using electrochemical synthesis include ... 

Various industrial pilot plants and full-scale operations, using radiation-chemical processing have been reported, with production rates -50 to -1000 tons per year (Spinks and Woods, 1990 Chutny and Kucera, 1974). Production rates less than -50 tons per year are not considered viable. These operations are or have been conducted in countries such as the United States, the former U.S.S.R., Japan, and France. However, some operations have also been reported in the former Czechoslovakia and Romania, especially in connection with petroleum industry. In the United States, chlorination of benzene to gammexane (hexachlorocyclohexane) was hotly pursued at one time by radiation or photoinitiation. Since the early seventies the activity has dwindled, presumably due to lack of demand and environmental considerations. 

Middox A process for delignifying wood pulp by the use of oxygen. Developed jointly by Air Products Chemicals, and Black Clawson Company. The process removes half of the lignin from the pulp, thereby halving the chlorine usage. 

PCDFs are also found in residual waste from the production of vinyl chloride and the chlor-alkali process for chlorine production. Factors favourable for the formation of PCDD/PCDFs are high temperatures, alkaline media, the presence of ultraviolet light, and the presence of radicals in the reaction mixture/chemical process (Fiedler, 1999 Hutzinger and Fiedler 1993). 

Chlorinated micropoUutants are harmful for man and environment due to their toxicity, persistence, and bioaccumulation. Persistent compounds are very stable and difficult to get metabolized and mineralized by biological and chemical processes in the environment, and as a result, they have become ubiquitous in water, sediments, and the atmosphere bioaccumulation is the result of the lipophilicity of these compounds. Polychlorinated dibenzodioxins and -furans (PCDD/F) are not produced purposely like many of other chlorinated technical products, such as chlorinated biocides DDT, lindane, and toxaphene. The production and use of persistent organic pollutants (POPs), the dirty dozen has now been banned worldwide by the Stockholm protocol. It should be mentioned that about 3000 halogenated products have now been isolated as natural products in plants, microorganisms, and animals," but the total amount of these products is much smaller compared to xenobiotics. 

Such processes lead to the formation of adsorbable halogenated organic compounds (AOX) in high concentrations. Typical concentrations found in a continuous antifelt treatment are shown in Table 4. The high dissolved organic carbon (DOC) determined in the baths is one of the sources for the formation of high concentrations of chlorinated compounds. The formation of chlorinated products is the result of chemical reactions directly with the fiber, with organic compounds released from the fibers, and with added auxiliaries. 

Sulfonated EPDMs are formulated to form a number of rubbery products including adhesives for footwear, garden hoses, and in the formation of calendered sheets. Perfluori-nated ionomers marketed as Nation (DuPont) are used for membrane applications including chemical-processing separations, spent-acid regeneration, electrochemical fuel cells, ion-selective separations, electrodialysis, and in the production of chlorine. It is also employed as a solid -state catalyst in chemical synthesis and processing. lonomers are also used in blends with other polymers. 

The formation of epoxides is synthetically a very important transformation. The indirect epoxidation of olefins (see Eq. 7) in the presence of electrogenerated chlorine (or bromine) [95] is a commercial process in which chlorine is recycled and not part of the product. The products such as propylene oxide are key intermediates in many further chemical processes. 

The manufacture of butadiene-based polymers and butadiene derivatives implies potential occupational exposure to a number of other chemical agents, which vary according to product and process, including other monomers (styrene, acrylonitrile, chloroprene), solvents, additives (e.g., activators, antioxidants, modifiers), catalysts, mineral oils, carbon black, chlorine, inorganic acids and caustic solutions (Fajen, 1986a.b Roberts, 1986). Styrene, benzene and toluene were measured in various departments of... 

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