Process/catalyst development replacement

Detal [Detergent alkylation] A process for making detergent alkylate, i.e., alkyl aromatic hydrocarbons such as linear alkyl benzenes, as intermediates for the manufacture of detergents, by reacting C10-C13 olefins with benzene in a fixed bed of an acid catalyst. Developed by UOP and CEPSA as a replacement for their Detergent Alkylate process, which uses liquid hydrogen fluoride as the catalyst. Demonstrated in a pilot plant in 1991 and first commercialized in Canada in 1996. Offered by UOP. 

Houdry The first catalytic petroleum cracking process, based on an invention by E. J. Houdiy in 1927, which was developed and commercialized by the Houdry Process Corporation. The process was piloted by the Vacuum Oil Company, Paulsboro, NJ, in the early 1930s. The catalyst was contained in a fixed bed. The first successful catalyst was an aluminosilicate mineral. Subsequently, other related catalysts were developed by Houdry in the United States, by I. G. Farbenindustrie in Germany, and by Imperial Chemical Industries in England. After World War II, the clay-based catalysts were replaced by a variety of synthetic catalysts, many based on alumino-silicates. Later, these too were replaced by zeolites. U.S. Patents 1,837,963 1,957,648 1,957,649. 

While subsequently replaced by further improved catalysts, the catalyst achieved high selectivity, was metal resistant at 7,800 ppm nickel plus vanadium, and achieved design projections during start-up and two months of commercial operation. Development of the catalyst served to stimulate research efforts by the catalyst industry to introduce other advanced residuum processing catalysts. 

Methanol was first produced commercially in 1830 by the pyrolysis of wood to produce wood alcohol. Almost a century later, a process was developed in Germany by BASF to produce synthetic methanol from coal synthesis gas. The first synthetic methanol plant was introduced by BASF in 1923 and in the United States by DuPont in 1927. In the late 1940s, natural gas replaced coal synthesis gas as the primary feedstock for methanol production. In 1966, ICI announced the development of a copper-based catalyst for use in the low-pressure synthesis of methanol. 

The soluble nickel catalyst developed by IFP for the oligomerization of alkenes applied in different Dimersol processes (see Section 13.1.3) can also be used in benzene hydrogenation to replace Raney nickel (IFP cyclohexane process).340... 

Traditionally, ethanol has been made from ethylene by sulfation followed by hydrolysis of the ethyl sulfate so produced. This type of process has the disadvantages of severe corrosion problems, the requirement for sulfuric acid reconcentration, and loss of yield caused by ethyl ether formation. Recently a successful direct catalytic hydration of ethylene has been accomplished on a commercial scale. This process, developed by Veba-Chemie in Germany, uses a fixed bed catalytic reaction system. Although direct hydration plants have been operated by Shell Chemical and Texas Eastman, Veba claims technical and economic superiority because of new catalyst developments. Because of its economic superiority, it is now replacing the sulfuric acid based process and has been licensed to British Petroleum in the United Kingdom, Publicker Industries in the United States, and others. By including ethanol dehydrogenation facilities, Veba claims that acetaldehyde can be produced indirectly from ethylene by this combined process at costs competitive with the catalytic oxidation of ethylene. 

Should MTBE be banned, what would be the logical replacement(s) There are several options available. Several refiners opted to build MTBE capacity and avoid purchasing the ether on the open market. MTBE units were an option to use the facility s isobutylenes. Several licensed processes can be used to convert existing MTBE units. Kvaerner and Lyondell Chemical Co. offer technologies to convert an MTBE unit to produce iso-octane, as shown in Fig. 18.27.12 Snamprogetti SpA and CDTECH also have an iso-octene/iso-octane process. These processes can use various feedstocks such as pure iso-butane, steam-cracked C4 raffinate, 50/50 iso-butane/iso-butene feeds, and FCC butane-butane streams. The process selectively dimerizes C4 olefins to iso-octene and then hydrogenates the iso-octene (di-iso-butene) into iso-octane. The processes were developed to provide an alternative to MTBE. The dimerization reactor uses a catalyst similar to that for MTBE processes thus, the MTBE reactor can easily be converted to... 

After 20 years, the microspherical silica alumina catalyst was replaced by zeolite catalyst, and development of new regeneration processes under different fluidization regimes was also on the way. 

Described are either the development of what is sometimes called a 2nd generation process (i.e., replacing an unsatisfactory existing process) or a new process to allow a chiral switch (to replace a racemic product and process). This is a problem-driven approach and the emphasis of most contribution is on the development of the catalyst, the catalytic process and also how to fit the new chemistry into the existing production facilities. Originators who want to defend an old product or companies who want to move into an existing market such as generics producers are concerned. 

The alkylation of isobutane with C4 olefins is currently carried out using liquid acids. In the last few years there was an increasing research effort in order to develop solid catalysts to replace the liquid acids. The major problem of the solid catalysts is a rapid deactivation due to coke deposition. Therefore, the development of a catalyst for this process requires the study of the regeneration and its optimization. 

There is a clear economic incentive to develop heterogeneous catalysts to replace conventional homogeneous catalysts in many industrial processes. Efforts to formulate highly active and selective solid catalysts have been the subject of intense research. One such process of interest is the condensation of alcohols, aldehydes and ketones, known as aldol condensation, which is used industrially for the synthesis of a series of products used extensively in various industries (/). 

Friedel-Crafts alkylation is one of the most frequently used and widely studied reactions in organic chemistry. Since the initial discovery by Charles Friedel and James Mason Crafts in 1877, a large number of applications have emerged for the construction of substituted aromatic compounds. Friedel-Crafts alkylation processes involve the replacement of C—H bond of an aromatic ring by an electrophilic partner in the presence of a Lewis acid or Bronsted acid catalyst. Particularly, catalytic asymmetric Friedel-Crafts alkylation is a very attractive, direct, and atom-economic approach for the synthesis of optically active aromatic compounds. However, it took more than 100 years from the discovery of this reaction until the first catalytic asymmetric Friedel-Crafts (AFC) alkylation of naphthol and ethyl pyruvate was realized by Erker in 1990. Nowadays, owing to continued efforts in developing... 

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