Ethylbenzene by alkylation of benzene

All lation. An exceUent example of alkylation is the Mobil-Badger process, which uses ZSM-5-type zeoHte to produce ethylbenzene by alkylation of benzene with ethylene (12,40) ... 

Zhang J, Li D, Fu J, Cao G. Process and apparatus for preparation of ethylbenzene by alkylation of benzene with dilute ethylene contained in dry gas by catalytic distillation. U.S. Patent Appl. 2001018545, 2001. 

Desulfurization of petroleum feedstock (FBR), catalytic cracking (MBR or FI BR), hydrodewaxing (FBR), steam reforming of methane or naphtha (FBR), water-gas shift (CO conversion) reaction (FBR-A), ammonia synthesis (FBR-A), methanol from synthesis gas (FBR), oxidation of sulfur dioxide (FBR-A), isomerization of xylenes (FBR-A), catalytic reforming of naphtha (FBR-A), reduction of nitrobenzene to aniline (FBR), butadiene from n-butanes (FBR-A), ethylbenzene by alkylation of benzene (FBR), dehydrogenation of ethylbenzene to styrene (FBR), methyl ethyl ketone from sec-butyl alcohol (by dehydrogenation) (FBR), formaldehyde from methanol (FBR), disproportionation of toluene (FBR-A), dehydration of ethanol (FBR-A), dimethylaniline from aniline and methanol (FBR), vinyl chloride from acetone (FBR), vinyl acetate from acetylene and acetic acid (FBR), phosgene from carbon monoxide (FBR), dichloroethane by oxichlorination of ethylene (FBR), oxidation of ethylene to ethylene oxide (FBR), oxidation of benzene to maleic anhydride (FBR), oxidation of toluene to benzaldehyde (FBR), phthalic anhydride from o-xylene (FBR), furane from butadiene (FBR), acrylonitrile by ammoxidation of propylene (FI BR)... 

Styrene is manufactured from ethylbenzene. Ethylbenzene [100-41-4] is produced by alkylation of benzene with ethylene, except for a very small fraction that is recovered from mixed Cg aromatics by superfractionation. Ethylbenzene and styrene units are almost always installed together with matching capacities because nearly all of the ethylbenzene produced commercially is converted to styrene. Alkylation is exothermic and dehydrogenation is endothermic. In a typical ethylbenzene—styrene complex, energy economy is realized by advantageously integrating the energy flows of the two units. A plant intended to produce ethylbenzene exclusively or mostly for the merchant market is also not considered viable because the merchant market is small and sporadic. 

Ethylbenzene is a major industrial chemical produced by alkylation of benzene. The pure chemical is used almost exclusively for st5Tene production. It is also present at up to 25% in technical grades of mixed xylenes and up to 15% in gasoline. 

Desorption of similar products from cumene- and propylene-deactivated parent H-mordenite is a result analogous to that of Venuto and Hamilton (3). They found that deactivation of rare earth X (REX) faujasite by alkylation of benzene with ethylene to ethylbenzene resulted in trapped products similar to those for deactivation with ethylene alone. 

Styrene is manufactured from ethylbenzene. Ethylbenzene is produced by alkylation of benzene witli ethylene. The reaction takes place on acidic catalysts and can be carried out either in the liquid or vapor phase. 

Over 90 percent of all ethylbenzene is produced by alkylation of benzene with ethylene in the presence of an acidic catalyst such as aluminum chloride or an acidic zeolite. Figure 10.13 shows a liquid phase alkylation process with zeolite catalyst. 

Friedel-Crajts alkylations are widely used in both the bulk and fine chemical industries. For example, ethylbenzene (the raw material for styrene manufacture) is manufactured by alkylation of benzene with ethylene (Fig. 2.12). 

Ethylbenzene (EB) is currently produced by alkylation of benzene with ethylene, primarily via two routes liquid-phase with AlCl, catalyst, or vapour-phase in catalytic fixed bed reactor (Ullmann, 2001). Examine the differences, as well as advantages and disadvantages of these routes. List pros and cons in selecting suitable reactors. 

For example, ia the iadustriaHy important alkylation of benzene with ethylene to ethylbenzene, polyethylbenzenes are also produced. The overall formation of polysubstituted products is minimized by recycling the higher ethylation products for the ethylation of fresh benzene (14). By adding the calculated equiUbrium amount of polyethylbenzene to the benzene feed, a high conversion of ethylene to monoethylbenzene can be achieved (15) (see also... 

Styrene. Commercial manufacture of this commodity monomer depends on ethylbenzene, which is converted by several means to a low purity styrene, subsequendy distilled to the pure form. A small percentage of styrene is made from the oxidative process, whereby ethylbenzene is oxidized to a hydroperoxide or alcohol and then dehydrated to styrene. A popular commercial route has been the alkylation of benzene to ethylbenzene, with ethylene, after which the cmde ethylbenzene is distilled to give high purity ethylbenzene. The ethylbenzene is direcdy dehydrogenated to styrene monomer in the vapor phase with steam and appropriate catalysts. Most styrene is manufactured by variations of this process. A variety of catalyst systems are used, based on ferric oxide with other components, including potassium salts, which improve the catalytic activity (10). 

Ethylbenzene can also be produced by catalytic alkylation of benzene with ethylene. Benzene is alkylated with ethylene in a fixed bed alkylator. An excess of benzene is used to suppress the formation of di- and triethyl- benzenes. The excess benzene is removed from the alkylate by fractionation and recycled to the alkylator. The ethylbenzene is separated from the polyalkylated benzenes which are in turn fed to a separate reactor. Here benzene is added to convert the polyalkylated benzenes to monoethylbenzene by transalkylation. 

Ethylbenzene (C6H5CH2CH3) is one of the Cg aromatic constituents in reformates and pyrolysis gasolines. It can be obtained by intensive fractionation of the aromatic extract, but only a small quantity of the demanded ethylbenzene is produced by this route. Most ethylbenzene is obtained by the alkylation of benzene with ethylene. Chapter 10 discusses conditions for producing ethylbenzene with benzene chemicals. The U.S. production of ethylbenzene was approximately 12.7 billion pounds in 1997. Essentially, all of it was directed for the production of styrene. 

Among the wide variety of organic reactions in which zeolites have been employed as catalysts, may be emphasized the transformations of aromatic hydrocarbons of importance in petrochemistry, and in the synthesis of intermediates for pharmaceutical or fragrance products.5 In particular, Friede 1-Crafts acylation and alkylation over zeolites have been widely used for the synthesis of fine chemicals.6 Insights into the mechanism of aromatic acylation over zeolites have been disclosed.7 The production of ethylbenzene from benzene and ethylene, catalyzed by HZSM-5 zeolite and developed by the Mobil-Badger Company, was the first commercialized industrial process for aromatic alkylation over zeolites.8 Other typical examples of zeolite-mediated Friedel-Crafts reactions are the regioselective formation of p-xylene by alkylation of toluene with methanol over HZSM-5,9 or the regioselective p-acylation of toluene with acetic anhydride over HBEA zeolites.10 In both transformations, the p-isomers are obtained in nearly quantitative yield. 

Benzene and para-xylene are the most sought after components from reformate and pygas, followed by ortho-xylene and meta-xylene. While there is petrochemical demand for toluene and ethylbenzene, the consumption of these carmot be discussed in the same way as the other four. Toluene is used in such a large quantity in gasoline blending that its demand as a petrochemical pales in comparison. Fthylbenzene from reformate and pygas is typically dealkylated to make benzene or isomerized to make xylenes. On-purpose production of petrochemical ethylbenzene (via ethylene alkylation of benzene) is primarily for use as an intermediate in the production of another petrochemical, styrene monomer. Ethylbenzene plants are typically built close coupled with styrene plants. 

Ethylbenzene is a high volume petrochemical used as the feed stock for the production of styrene via dehydrogenation. Ethylbenzene is currently made by ethylene alkylation of benzene and can be purified to 99.9%. Ethylbenzene and styrene plants are usually built in a single location. There is very little merchant sale of ethylbenzene, and styrene production is about 30x10 t/year. For selective adsorption to be economically competitive on this scale, streams with sufficiently high concentration and volume of ethylbenzene would be required. Hence, although technology has been available for ethylbenzene extraction from mixed xylenes, potential commercial opportunities are limited to niche applications. 

Alkylation of benzene with ethylene gives ethylbenzene,283,284,308,309 which is the major source of styrene produced by catalytic dehydrogenation. High benzene ethylene ratios are applied in all industrial processes to minimize polyethylation. Polyethylbenzenes formed are recycled and transalkylated with benzene. Yields better than 98% are usually attained. Reactants free of sulfur impurities and water must be used. 

Friedel-Crafts catalysts (corrosion, continuous catalyst makeup). Although it gives a broader spectrum of alkylated products, recycling and transalkylation ensure high ethylbenzene yields. Steamed ZSM-5 and chrysozeolite ZSM-5 were shown by Union Carbide to afford ethylbenzene with high selectivity in the alkylation of benzene with ethanol.317... 

Vapor-phase alkylation of benzene by ethene and propene over HY, LaY, and REHY has been studied in a tubular flow reactor. Transient data were obtained. The observed rate of reaction passes through a maximum with time, which results from build-up of product concentration in the zeolite pores coupled with catalyst deactivation. The rate decay is related to aromatic olefin ratio temperature, and olefin type. The observed rate fits a model involving desorption of product from the zeolite crystallites into the gas phase as a rate-limiting step. The activation energy for the desorption term is 16.5 heal/mole, approximately equivalent to the heat of adsorption of ethylbenzene. For low molecular weight alkylates intracrystalline diffusion limitations do not exist. 

Alkylation of benzene for the production of ethylbenzene, the raw material for making styrene and subsequently synthetic rubber, was also greatly expanded during the war because of the shortage of natural rubber. The catalyst in most of the original ethylbenzene units was aluminum chloride, but other catalysts are now preferred by many refiners. Alkylation for the production of ethylbenzene was the first large-scale alkylation process used for the production of petrochemicals. Since that time, others, such as cumene, dodecylbenzene, alkylated phenols, diisopropylbenzene, and secondary butylbenzene, have been added to the list, and others have been developed and should soon be in commercial production. 

Ethylbenzene was the first petrochemical to be produced by petroleum refiners in large quantities. It is made by the alkylation of benzene by ethylene. Aluminum chloride promoted with ethyl chloride was originally the predominant catalyst used for the reaction, but solid phosphoric acid has been used more recently and is becoming more popular. Some of the newer fluoride-type catalysts are expected to become quite popular. 

As another aspect in the alkylation of benzene with ethylene, side reaction selectivity is also a key problem In this present case, xylenes are the major by-products of the reaction. The main products ethylbenzene and the by-products xylene are isomers with very close boiling points, which cause great difficulty in separation xylenes from ethylbenzene. 

Cumene capacity topped 9.5 million metric tons in 1998 and is projected to reach 10.4 million metric tons by the end of 2003 (19). Like ethylbenzene, cumene is used almost exclusively as a chemical intermediate. Its primary use is in the coproduction of phenol and acetone through cumene peroxidation. Phenolic resins and bisphenol A are the main end uses for phenol. Bisphenol A, which is produced from phenol and acetone, has been the main driver behind increased phenol demand. Its end use applications are in polycarbonate and epoxy resins. The growth rate of cumene is closely related to that of phenol and is expected to be approximately 5.1% per year worldwide over the next five years. Process technologies for both chemicals have been moving away from conventional aluminum chloride and phosphoric acid catalyzed Friedel-Crafts alkylation of benzene, toward zeolite-based processes. 

Application State-of-the-art technology to produce high-purity ethylbenzene (EB) by liquid-phase alkylation of benzene with ethylene. The Lum-mus/UOP EBOne process uses specially formulated, proprietary zeolite catalyst from UOP. The process can handle a wide range of ethylene feed compositions ranging from chemical (70%) to polymer grade (100%). 

Ethylbenzene is commercially produced almost entirely as an intermediate for the manufacture of styrene. Since only a limited amount can be made by the superfractionation of Ce petroleum aromatics, most ethylbenzene is produced by the alkylation of benzene with ethylene. The alkylation reaction can occur eUher in the vapor phase or the liquid phase. A number of proven processes exist. The liquid phase processes using aluminum chloride catalysts are currently the most widely used. The purpose of this paper is to describe a new and improved version of this latter process which has been commercialized. 

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