Production alternative processes

There can be an element of maintenance costs that is fixed and an element which is variable. Fixed maintenance costs cover routine maintenance such as regular maintenance on safety valves which must be carried out irrespective of the rate of production. There also can be an element of maintenance costs which is variable. This arises from the fact that certain items of equipment can need more maintenance as the production rate increases. Also, royalties which cover the cost of purchasing another company s process technology may have different bases. Royalties may be a variable cost, since they can sometimes be paid in proportion to the rate of production. Alternatively, the royalty might be a single-sum payment at the beginning of the project. In this case, the single-sum payment will become part of the project s capital investment. As such, it will be included in the annual capital repayment, and this becomes part of the fixed cost. 

The nameplate capacities for acetaldehyde production for the United States in 1989 are shown in Table 5 (120). Synthetic pyridine derivatives, peracetic acid, acetate esters by the Tischenko route, and pentaerythritol account for 40% of acetaldehyde demand. This sector may show strong growth in some products but all of these materials maybe prepared from alternative processes. 

The unit Kureha operated at Nakoso to process 120,000 metric tons per year of naphtha produces a mix of acetylene and ethylene at a 1 1 ratio. Kureha s development work was directed toward producing ethylene from cmde oil. Their work showed that at extreme operating conditions, 2000°C and short residence time, appreciable acetylene production was possible. In the process, cmde oil or naphtha is sprayed with superheated steam into the specially designed reactor. The steam is superheated to 2000°C in refractory lined, pebble bed regenerative-type heaters. A pair of the heaters are used with countercurrent flows of combustion gas and steam to alternately heat the refractory and produce the superheated steam. In addition to the acetylene and ethylene products, the process produces a variety of by-products including pitch, tars, and oils rich in naphthalene. One of the important attributes of this type of reactor is its abiUty to produce variable quantities of ethylene as a coproduct by dropping the reaction temperature (20—22). 

Chemical products are produced from technical-grade oxide in two very different ways. Molybdenum trioxide can be purified by a sublimation process because molybdenum trioxide has an appreciable vapor pressure above 650°C, a temperature at which most impurities have very low volatiUty. The alternative process uses wet chemical methods in which the molybdenum oxide is dissolved in ammonium hydroxide, leaving the gangue impurities behind. An ammonium molybdate is crystallized from the resulting solution. The ammonium molybdate can be used either directly or thermally decomposed to produce the pure oxide, MoO. ... 

The reaction is completed after 6—8 h at 95°C volatiles, water, and some free phenol are removed by vacuum stripping up to 140—170°C. For resins requiring phenol in only trace amounts, such as epoxy hardeners, steam distillation or steam stripping may be used. Both water and free phenol affect the cure and final resin properties, which are monitored in routine quaHty control testing by gc. OxaHc acid (1—2 parts per 100 parts phenol) does not require neutralization because it decomposes to CO, CO2, and water furthermore, it produces milder reactions and low color. Sulfuric and sulfonic acids are strong catalysts and require neutralization with lime 0.1 parts of sulfuric acid per 100 parts of phenol are used. A continuous process for novolak resin production has been described (31,32). An alternative process for making novolaks without acid catalysis has also been reported (33), which uses a... 

Bayer marketed PPS compounds in the United States under the trade name Tedur, but the company has exited the PPS business. PPS is also marketed in the United States by GE Plastics, whose source of neat resin is Tosoh Corporation of Japan. GE Plastics markets PPS under the trade name Supec PPS. Patent activity by Tennessee Eastman describes an alternative process for the production of poly(phenylene sulfide/disulfide), although samples of such product have not appeared as of early 1996. Both Phillips and Hoechst Celanese have aimounced plans to debotdeneck their existing U.S. faciUties in order to meet anticipated market growth. 

Alternative Processes for Aluminum Production. In spite of its industrial dominance, the HaH-HAroult process has several inherent disadvantages. The most serious is the large capital investment requited resulting from the multiplicity of units (250 —1000 cells in a typical plant), the cost of the Bayer aluniina-puriftcation plant, and the cost of the carbon—anode plant (or paste plant for Soderberg anodes). Additionally, HaH-HAroult cells requite expensive electrical power rather than thermal energy, most producing countries must import alumina or bauxite, and petroleum coke for anodes is in limited supply. 

Alternative Processes. Bayer processing of bauxite is the most economical method for Al(OH)2 and AI2O2 production however, the... 

In the second proposed alternative process, tert-huty hypochlorite, formed from the reaction of chlorine and tert-huty alcohol, reacts with propylene and water to produce the chlorohydrin. The alcohol is a coproduct and is recycled to generate the hypochlorite (114—116). No commercialisation of the hypochlorous acid and tert-huty hypochlorite processes for chlorohydrin production is known. 

Conversion Processes. A number of options exist for handling concentrated sulfur dioxide streams. One option is the sale of a Hquid sulfur dioxide product. Alternatively, the sulfur dioxide can be converted to elemental sulfur or to sulfuric acid. 

There are currentiy three important processes for the production of isobutylene (/) the extraction process using an acid to separate isobutylene (2) the dehydration of tert-huty alcohol, formed in the Arco s Oxirane process and (3) the cracking of MTBE. The expected demand for MTBE wHl preclude the third route for isobutylene production. Since MTBE is likely to replace tert-huty alcohol as a gasoline additive, the second route could become an important source for isobutylene. Nevertheless, its avaHabHity wHl be limited by the demand for propylene oxide, since it is only a coproduct. An alternative process is emerging that consists of catalyticaHy hydroisomerizing 1-butene to 2-butenes (82). In this process, trace quantities of butadienes are also hydrogenated to yield feedstocks rich in isobutylene which can then be easHy separated from 2-butenes by simple distHlation. 

An alternative process for opening bastnasite is used ia Chiaa high temperature roastiag with sulfuric acid followed by an aqueous leach produces a solution containing the Ln elements. Ln is then precipitated by addition of sodium chloride as a mixed sulfate. Controlled precipitation of hydroxide can remove impurities and the Ln content is eventually taken up ia HCl. The initial cerium-containing product, oace the heavy metals Sm and beyond have been removed, is a light lanthanide (La, Ce, Pr, and Nd) rare-earth chloride. 

In the production of a-olefins, ethylene reacts with an aluminum alkyl at relatively low temperature to produce a higher aLkylalumiaum. This is then subjected to a displacement reaction with ethylene at high temperatures to yield a mixture of a-olefins and triethylalumiaum. In an alternative process, both reactions are combiaed at high temperatures and pressures where triethylalumiaum fuactioas as a catalyst ia the polymerization process. 

When to Scrap an Existing Process Let us suppose that a company invests 50,000 in a manufacturing process that has positive net annual flows (after tax) Acp of 10,000 in each year. During the third year of operation, an alternative process becomes available. The new process would require an investment of 40,000 but would have positive net annual cash flows (after tax) of 20,000 in each year. The cost of capital is 10 percent, and it is estimated that a market will exist for the product for at least 6 more years. Should the company continue with the existing process (project H), or should it scrap project H and adopt the new process (project 1) ... 

Is it possible to completely eliminate hazardous raw materials, process intermediates, or by-products by using an alternative process or chemistry ... 

The three isomers constituting n-hutenes are 1-hutene, cis-2-hutene, and trans-2-hutene. This gas mixture is usually obtained from the olefinic C4 fraction of catalytic cracking and steam cracking processes after separation of isobutene (Chapter 2). The mixture of isomers may be used directly for reactions that are common for the three isomers and produce the same intermediates and hence the same products. Alternatively, the mixture may be separated into two streams, one constituted of 1-butene and the other of cis-and trans-2-butene mixture. Each stream produces specific chemicals. Approximately 70% of 1-butene is used as a comonomer with ethylene to produce linear low-density polyethylene (LLDPE). Another use of 1-butene is for the synthesis of butylene oxide. The rest is used with the 2-butenes to produce other chemicals. n-Butene could also be isomerized to isobutene. ... 

Once formed, and depending on the nature of the nucleophile, the tetrahedral alkoxide intermediate can undergo either of two further reactions, as shown in Figure 2. Often, the tetrahedral alkoxide intermediate is simply protonated by water or acid to form an alcohol product. Alternatively, the tetrahedral intermediate can be protonated and expel the oxygen to form a new double bond between the carbonyl carbon and the nucleophile. We ll study both processes in detail in Chapter 19. 

A homogeneous catalyst is one that is present in the same phase as the reactants. It speeds up the reaction by forming a reactive intermediate that decomposes to give products. In this way, the catalyst provides an alternative process of lower activation energy. 

An alternative process for the synthesis of vinylepoxides was clearly needed, so reactions with stoichiometric amounts of chiral sulfide were investigated (Scheme 9.16a) [74]. Indeed, when benzyl sulfonium salt 20 was treated with unsaturated aldehydes, the ees and des were high in all cases, whereas the yields [75] were highly substrate-dependent. The same products could be formed by treatment of an unsaturated sulfonium salt with benzaldehyde, but the yields and se-lectivities were generally slightly lower. 

Filter aids are widely used in die fermentation industry to improve the efficiency of filtration. It is a pre-coated filter medium to prevent blockage or blinding of the filter by solids, which would otherwise wedge diemselves into the pores of the cloth. Filter aid can be added to the fermentation broth to increase the porosity of the cake as it formed. This is only recommended when fermentation product is extracellular. Filter aid adds to the cost of filtration. The minimum quantity needed to achieve the desired result must be established experimentally. Fermentation broths can be pretreated to improve filtration characteristics. Heating to denature proteins enhances the filterability of mycelial broths such as in penicillin production. Alternatively, electrolytes may be added to promote coagulation of colloids into larger, denser particles, which are easier to filter. The filtration process is affected by the viscosity and composition of the broth, and the cell cake.5... 

In summary, when considering alternative processes for producing plastic and RP products, the major concerns usually involve (1) limitations that may be imposed by the material, because not all materials can be processed by all methods (2) limitations imposed by the design, such as the size, singlepiece versus multiple-piece construction, a closed or open shape, and the level of dimensional and tolerance accuracy required ... 

We have found in our studies that the use of the lithium counter ion in the base is essential for successful reaction with regiochemical control and allows cyclization to proceed under mild thermal conditions. In contrast, use of sodium (NaH, NaN(SiMe3)2) or potassium (KH, KN(SiMe3)2) bases require elevated temperatures, and results in poor yields of the desired product, and a mixture of several by-products, including the regioisomeric 4-hydroxymethy-2-oxazolidinone,6 resulting from alternate processes. Thus, the lithium ion plays a very important role in the mechanism of this reaction. 

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