MIBK

Aqueous solutions buffered to a pH of 5.2 and containing known total concentrations of Zn + are prepared. A solution containing ammonium pyrrolidinecarbodithioate (APCD) is added along with methyl isobutyl ketone (MIBK). The mixture is shaken briefly and then placed on a rotary shaker table for 30 min. At the end of the extraction period the aqueous and organic phases are separated and the concentration of zinc in the aqueous layer determined by atomic absorption. The concentration of zinc in the organic phase is determined by difference and the equilibrium constant for the extraction calculated. 

The following data have been reported for the gas chromatographic analysis of p-xylene and methylisobutylketone (MIBK) on a capillary column. ... 

Methyl Isobutyl Ketone. Methyl isobutyl ketone (MIBK) (4-methyl-2-pentanone), (CH2)2CHCH2COCH2, is an industrially important solvent which after methyl methacrylate and bisphenol A is the third largest tonnage product obtained from acetone. 

MIBK is a flammable, water-white Hquid that boils at 116°C. It is sparingly soluble in water, but is miscible with common organic solvents. It forms an a2eotrope with water as shown in Table 2. Condensation of MIBK with another methyl ketone can produce ketones containing 9—15 carbons. For example, condensation with acetone produces diisobutyl ketone, and self-condensation of two MIBK molecules produces 2,6,8-trimethyl-4-nonanone [123-17-1]. Condensation with 2-ethylhexanal gives 1-tetradecanol (7-ethyl-2-methyl-4-undecanol), avaluable surfactant intermediate (58). 

The one-step route from 2-propanol coproduces diisobutyl ketone and acetone, and is practiced in the United States by Union Carbide (61). The details of a vapor-phase 2-propanol dehydrogenation and condensation process for the production of acetone, MIBK, and higher ketones have been described in recent patents (62,63). The process converts an a2eotropic 2-propanol—water feed over a copper-based catalyst at 220°C and produces a product mixture containing 2-propanol (11.4%), acetone (52.4%), MIBK (21.6%), diisobutyl ketone (6.5%), and 4-methyl-2-pentanol (2.2%). 

Figure 2 illustrates the three-step MIBK process employed by Hibernia Scholven (83). This process is designed to permit the intermediate recovery of refined diacetone alcohol and mesityl oxide. In the first step acetone and dilute sodium hydroxide are fed continuously to a reactor at low temperature and with a reactor residence time of approximately one hour. The product is then stabilized with phosphoric acid and stripped of unreacted acetone to yield a cmde diacetone alcohol stream. More phosphoric acid is then added, and the diacetone alcohol dehydrated to mesityl oxide in a distillation column. Mesityl oxide is recovered overhead in this column and fed to a further distillation column where residual acetone is removed and recycled to yield a tails stream containing 98—99% mesityl oxide. The mesityl oxide is then hydrogenated to MIBK in a reactive distillation conducted at atmospheric pressure and 110°C. Simultaneous hydrogenation and rectification are achieved in a column fitted with a palladium catalyst bed, and yields of mesityl oxide to MIBK exceeding 96% are obtained. 

The Tokuyama Soda single-step catalyst consists of a zirconium phosphate catalyst loaded with 0.1—0.5 wt % paHadium (93—97). Pilot-plant data report (93) that at 140°C, 3 MPa, and a H2 acetone mole ratio of 0.2, the MIBK selectivity is 95% at an acetone conversion of 30%. The reactor product does not contain light methyl substituted methyl pentanes, and allows MIBK recovery in a three-column train with a phase separator between the first and second columns. 

Sumitomo Chemical Co. (98—100) and Mitsubishi Kasei Co. (101) have patented single-step catalysts containing niobium and palladium. A Sumitomo example reports 93.5% MIBK selectivity at 41.8% acetone conversion and conditions of 160°C and 2 MPa. Other significant processes have been reported (60,102—110). 

Health and Safety Factors. Like other low molecular weight ketones, MIBK is an anesthetic chemical with no highly cumulative toxicological effects. Inhalation of vapors can irritate mucous membranes. 

MIBK is a highly effective separating agent for metals from solutions of their salts and is used in the mining industries to extract plutonium from uranium, niobium from tantalum, and zirconium from hafnium (112,113). MIBK is also used in the production of specialty surfactants for inks (qv), paints, and pesticide formulations, examples of which are 2,4,7,9-tetramethyl-5-decyn-4,7-diol and its ethoxylated adduct. Other appHcations include as a solvent for adhesives and wax/oil separation (114), in leather (qv) finishing, textile coating, and as a denaturant for ethanol formulations. 

In addition to DAA s use in the production of MIBK, DAA also finds use as a specialty reaction intermediate. Hydrogenation of DAA at 100°C and 30 MPa (83) yields hexylene glycol ( 1.43/kg, October 1994), widely used in castor oil-based hydrauhc brake fluids and as a solvent. Reaction of /)-phenetidine [156-43-4] with DAA synthesizes Monsanto s Santoquin (ethoxyquin) [91-53-2] (149), an antioxidant used in animal feeds and also as a mbber additive. Diacetone alcohol (acetone-free) was available at 1.32/kg as of October 1994. 

Ma.nufa.cture. Mesityl oxide is produced by the Hquid-phase dehydration of diacetone alcohol ia the presence of acidic catalysts at 100—120°C and atmospheric pressure. As a precursor to MIBK, mesityl oxide is prepared ia this manner ia a distillation column ia which acetone is removed overhead and water-saturated mesityl oxide is produced from a side-draw. Suitable catalysts are phosphoric acid (177,178) and sulfuric acid (179,180). The kinetics of the reaction over phosphoric acid have been reported (181). 

MIBK Direct Conversion ofMcetone over Heterogeneous Catalyst-Sumitomo, Process Evaluation Research Planning (PERP), Topical Reports, Vol. Ill, Chem Systems Inc., Tarrytown, NY, 1988. 

Another solvent extraction scheme uses the mixed anhydrous chlorides from a chlorination process as the feed (28). The chlorides, which are mostly of niobium, tantalum, and iron, are dissolved in an organic phase and are extracted with 12 Ai hydrochloric acid. The best separation occurs from a mixture of MIBK and diisobutyl ketone (DIBK). The tantalum transfers to the hydrochloric acid leaving the niobium and iron, the DIBK enhancing the separation factor in the organic phase. Niobium and iron are stripped with hot 14—20 wt % H2SO4 which is boiled to precipitate niobic acid, leaving the iron in solution. 

Solvents used for dewaxing are naphtha, propane, sulfur dioxide, acetone—benzene, trichloroethylene, ethylenedichloride—benzene (Barisol), methyl ethyl ketone—benzene (benzol), methyl -butyl ketone, and methyl / -propyl ketone. Other solvents in commercial use for dewaxing include /V-methylpyrrolidinone, MEK—MIBK (methyl isobutyl ketone), dichloroethane—methylene dichloride, and propfyene—acetone. 

Formulator s Dilemma. The regulatory discussion included a listing of solvents designated as HAP compounds. Emissions of these solvents are to be significantly reduced. For many appHcations this means that less is to be allowed. In a situation where the allowed VOC emission levels are also being reduced, the formulator would like to use the most effective solvents available. In the past, MEK and MIBK were frequently used as active solvents and aromatic hydrocarbons as diluents. These solvents have been popular because they are cost-effective. 

Reformulating to reduce HAP solvents frequently means that solvent blend costs increase. The newer blends are generally not be as effective. For example, many coatings were usually formulated using ketones as the active solvents with aromatic hydrocarbons as diluents. This combination produced the most cost-effective formulations. However, when MEK, MIBK, toluene, and xylene became HAP compounds, less-effective solvents had to be used for reformulation. Esters are the most common ketone replacements, and aUphatic diluents would replace the aromatic hydrocarbons. In this situation, more strong solvent is required compared to the ketone/aromatic formulation and costs increase. The combination of reduced VOC emissions and composition constraints in the form of HAP restrictions have compHcated the formulator s task. 

Fig. 2. The processing of Ta—Nb raw materials where MIBK = methyl isobutyl ketone.

In the initial thiocyanate-complex Hquid—Hquid extraction process (42,43), the thiocyanate complexes of hafnium and zirconium were extracted with ether from a dilute sulfuric acid solution of zirconium and hafnium to obtain hafnium. This process was modified in 1949—1950 by an Oak Ridge team and is stiH used in the United States. A solution of thiocyanic acid in methyl isobutyl ketone (MIBK) is used to extract hafnium preferentially from a concentrated zirconium—hafnium oxide chloride solution which also contains thiocyanic acid. The separated metals are recovered by precipitation as basic zirconium sulfate and hydrous hafnium oxide, respectively, and calcined to the oxide (44,45). This process is used by Teledyne Wah Chang Albany Corporation and Western Zirconium Division of Westinghouse, and was used by Carbomndum Metals Company, Reactive Metals Inc., AMAX Specialty Metals, Toyo Zirconium in Japan, and Pechiney Ugine Kuhlmann in France. 

Ternary-phase equilibrium data can be tabulated as in Table 15-1 and then worked into an electronic spreadsheet as in Table 15-2 to be presented as a right-triangular diagram as shown in Fig. 15-7. The weight-fraction solute is on the horizontal axis and the weight-fraciion extraciion-solvent is on the veriical axis. The tie-lines connect the points that are in equilibrium. For low-solute concentrations the horizontal scale can be expanded. The water-acetic acid-methylisobutylketone ternary is a Type I system where only one of the binary pairs, water-MIBK, is immiscible. In a Type II system two of the binary pairs are immiscible, i.e. the solute is not totally miscible in one of the liquids. 

Water Acetic acid MIBK Water Acetic acid MIBK ... 

TABLE 15-2 Spreadsheet for Right Triangular Ternary Diagram of Water/Acetic Acid/MIBK Liquid-Liquid-Equilibrium Data at 25" C in Fig. 15-7... 

Wt. fraction Variable Acetic acid X MIBK Y1 MIBK Y2 1 — wf AA Y3... 

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