Monsanto high-water technology

In 1996 BP announced the commercialization of their version of a low-water methanol carbonylation technology named Cativa based upon a promoted iridium catalyst. The Cativa process replaced the high-water Monsanto process which had been used by BP. 

In the 1990s, BP re-examined the iridium-catalyzed methanol carbonylation chemistry first discovered by Paulik and Roth and later defined in more detail by Forster [20]. The thrust of this research was to identify an improved methanol carbonylation process using Ir as an alternative to Rh. This re-examination by BP led to the development of a low-water iridium-catalyzed process called Cativa [20]. Several advantages were identified in this process over the Rh-catalyzed high-water Monsanto technology. In particular, the Ir catalyst provides high carbonylation rates at low water concentrations with excellent catalyst stability (less prone to precipitation). The catalyst system does not require high levels of iodide salts to stabilize the catalyst. Fewer by-products are formed, such as propionic acid and acetaldehyde condensation products which can lead to low levels of unsaturated aldehydes and heavy alkyl iodides. Also, CO efficiency is improved. 

Since the development of Cativa , BP has converted three world-scale acetic acid plants from the old Rh-based high-water Monsanto technology to the Ir-based low-water process. Significant capital and operating cost savings were achieved from the conversion of a Rh-based process to an Ir-based process. Also, the start-up in 2000 of a 500 X 10 metric ton per year acetic acid plant in Malaysia uses the Cativa process [20d]. 

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