Ethylene impurities

Small quantities of methanol and ethanol are sometimes added to the C3S in pipelines to protect against freezing because of hydrate formation. Although the beta zeolite catalyst is tolerant of these alcohols, removing them from the feed by a water wash may still be desirable to achieve the lowest possible levels of EB or cymene in the cumene product. Cymene is formed by the alkylation of toluene with propylene. The toluene may already be present as an impurity in the benzene feed, or it may be formed in the alkylation reactor from methanol and benzene. Ethylbenzene is primarily formed from ethylene impurities in the propylene feed. However, similar to cymene, EB can also be formed from ethanol. 

Small amounts of ethylene impurity in the monomer had been suggested to explain the presence of the tetramethylenes in PP. However, the processes would have to involve a sequence of 1,2-propene insertion, ethylene insertion and 2,1-propene insertion in order to... 

In the past, the polymer-grade product specification called for 99.90% pure ethylene. However, there recently has been an increased demand for greater purities, up to 99.97% ethylene. Impurities in the product consist of methane and ethane, usually in the ratio of 2.4 to 3.0 mol of ethane per mol of methane. The ethylene recovered as product should not be less than 94% of that present in the feed stream. 

This is called a technical or cmde grade of terephthaUc acid, but the purity is typically greater than 99%. It is not, however, pure enough for the poly(ethylene terephthalate) made from it to reach the required degree of polymerization. The main impurity is 4-formylbenzoic acid [619-66-9] which is incompletely oxidized -xylene and is monofunctional with regard to esterification. 4-Formylbenzoic acid is usually referred to as 4-carboxybenzaldehyde (4-CBA) in the industry. 

Other by-products include acetone, carbonaceous material, and polymers of propylene. Minor contaminants arise from impurities in the feed. Ethylene and butylenes can form traces of ethyl alcohol and 2-butanol. Small amounts of / -propyl alcohol carried through into the refined isopropyl alcohol can originate from cyclopropane [75-19-4] in the propylene feed. Acetone, an oxidation product, also forms from thermal decomposition of the intermediate sulfate esters, eg. 

The ethylene feedstock used in most plants is of high purity and contains 200—2000 ppm of ethane as the only significant impurity. Ethane is inert in the reactor and is rejected from the plant in the vent gas for use as fuel. Dilute gas streams, such as treated fluid-catalytic cracking (FCC) off-gas from refineries with ethylene concentrations as low as 10%, have also been used as the ethylene feedstock. The refinery FCC off-gas, which is otherwise used as fuel, can be an attractive source of ethylene even with the added costs of the treatments needed to remove undesirable impurities such as acetylene and higher olefins. Its use for ethylbenzene production, however, is limited by the quantity available. Only large refineries are capable of deUvering sufficient FCC off-gas to support an ethylbenzene—styrene plant of an economical scale. 

By-products from EDC pyrolysis typically include acetjiene, ethylene, methyl chloride, ethyl chloride, 1,3-butadiene, vinylacetylene, benzene, chloroprene, vinyUdene chloride, 1,1-dichloroethane, chloroform, carbon tetrachloride, 1,1,1-trichloroethane [71-55-6] and other chlorinated hydrocarbons (78). Most of these impurities remain with the unconverted EDC, and are subsequendy removed in EDC purification as light and heavy ends. The lightest compounds, ethylene and acetylene, are taken off with the HCl and end up in the oxychlorination reactor feed. The acetylene can be selectively hydrogenated to ethylene. The compounds that have boiling points near that of vinyl chloride, ie, methyl chloride and 1,3-butadiene, will codistiU with the vinyl chloride product. Chlorine or carbon tetrachloride addition to the pyrolysis reactor feed has been used to suppress methyl chloride formation, whereas 1,3-butadiene, which interferes with PVC polymerization, can be removed by treatment with chlorine or HCl, or by selective hydrogenation. 

A selective poison is one that binds to the catalyst surface in such a way that it blocks the catalytic sites for one kind of reaction but not those for another. Selective poisons are used to control the selectivity of a catalyst. For example, nickel catalysts supported on alumina are used for selective removal of acetjiene impurities in olefin streams (58). The catalyst is treated with a continuous feed stream containing sulfur to poison it to an exacdy controlled degree that does not affect the activity for conversion of acetylene to ethylene but does poison the activity for ethylene hydrogenation to ethane. Thus the acetylene is removed and the valuable olefin is not converted. 

In all of the ethylene polymerization processes, the catalyst is sensitive to feed impurities and is poisoned by most polar compounds. Many of the properties of the polymer are determined by polymerization conditions, but catalyst composition and condition are critical determinants as well. 

Determination. The most accurate (68) method for the deterrnination of copper in its compounds is by electrogravimetry from a sulfuric and nitric acid solution (45). Pure copper compounds can be readily titrated using ethylene diamine tetracetic acid (EDTA) to a SNAZOXS or Murexide endpoint. lodometric titration using sodium thiosulfate to a starch—iodide endpoint is one of the most common methods used industrially. This latter titration is quicker than electrolysis, almost as accurate, and much more tolerant of impurities than is the titration with EDTA. Gravimetry as the thiocyanate has also been used (68). 

Isomerization of ethylene oxide to acetaldehyde occurs at elevated temperatures ia the presence of catalysts such as activated alumina, phosphoric acid, and metallic phosphates (75). Iron oxides also catalyze this reaction. Acetaldehyde may be found as a trace impurity ia ethylene oxide. 

The air process has similar purity requirements to the oxygen process. The ethane content of ethylene is no longer a concern, due to the high cycle purge flow rate. Air purification schemes have been used to remove potential catalyst poisons or other unwanted impurities ia the feed. 

Ethylene Oxide Purification. The main impurities ia ethylene oxide are water, carbon dioxide, and both acetaldehyde and formaldehyde. Water and carbon dioxide are removed by distillation ia columns containing only rectifying or stripping sections. Aldehydes are separated from ethylene... 

Ethylene oxide is sold as a high purity chemical, with typical specifications shown ia Table 14. This purity is so high that only impurities are specified. There is normally no assay specification. Proper sampling techniques are critical to avoid personal exposure and prevent contamination of the sample with trace levels of water. A complete review and description of analytical methods for pure ethylene oxide is given ia Reference 228. 

Polymerization processes are characterized by extremes. Industrial products are mixtures with molecular weights of lO" to 10. In a particular polymerization of styrene the viscosity increased by a fac tor of lO " as conversion went from 0 to 60 percent. The adiabatic reaction temperature for complete polymerization of ethylene is 1,800 K (3,240 R). Heat transfer coefficients in stirred tanks with high viscosities can be as low as 25 W/(m °C) (16.2 Btu/[h fH °F]). Reaction times for butadiene-styrene rubbers are 8 to 12 h polyethylene molecules continue to grow lor 30 min whereas ethyl acrylate in 20% emulsion reacts in less than 1 min, so monomer must be added gradually to keep the temperature within hmits. Initiators of the chain reactions have concentration of 10" g mol/L so they are highly sensitive to poisons and impurities. 

---