Propylene isopropyl alcohol

Propene is used as a starting material for numerous other compounds. Chief among these are isopropyl alcohol, acrylonitrile, and propylene oxide. Isopropyl alcohol results from the hydration of propylene during cracking and is the primary chemical derived from propylene. Isopropyl alcohol is used as a solvent, antifreeze, and as rubbing alcohol, but its major use is for the production of acetone. Acrylonitrile is used primarily as a monomer in the production of acrylic fibers. Polymerized acrylonitrile fibers are produced under the trade names such as Orion (DuPont) and Acrilan (Monsanto). Acrylonitrile is also a reactant in the synthesis of dyes, pharmaceuticals, synthetic rubber, and resins. Acrylonitrile production occurs primarily through ammoxidation of propylene CH3- CH = CH2 + NH3 + 1.5 02—> CH2 = CH - C = N + 3 H20. 

Propan-2-ol (2-propanol, isopropyl alcohol) is made by the catalytic hydration of propylene. Isopropyl alcohol is commonly used as rubbing alcohol (rather than ethanol) because it has less of a drying effect on the skin, and it is not regulated and... 

PROPYLENE - ISOPROPYL ALCOHOL, acrylonitrile. ACETONE. POLYPROPYLENE. 

Figure 10.3a shows a simplified fiowsheet for the production of isopropyl alcohol by the direct hydration of propylene. Different reactor technologies are available for the process, and separation and recycle systems vary, but Fig. 10.3a is representative. Propylene... 

Figure 10.3 Outline flowsheet for the production of isopropyl alcohol by direct hydration of propylene. (From Smith and Petela, Chem. Eng., 513 24, 1991 reproduced by permission of the Institution of Chemical Engineers.)...

In general, the best way to deal with a feed impurity is to purify the feed before it enters the process. Let us return to the isopropyl alcohol process from Fig. 10.3. Propylene is fed to the process containing propane as a feed impurity. In Fig. 10.3 the propane is removed from the process using a purge. This causes waste of... 

If desired, the alcohol may be identified as the 3 5-dinitrobenzoate (Section 111,27) it is then best to repeat the experiment on a larger scale and to replace the dilute hydrochloric acid by dilute sulphuric acid. It must, however, be pointed out that the reaction is not always so simple as indicated in the above equation. Olefine formation and rearrangement of the alcohol sometimes occur thus n-prop3 lamine yields n-propyl alcohol, isopropyl alcohol and propylene. 

Production of acetone by dehydrogenation of isopropyl alcohol began in the early 1920s and remained the dominant production method through the 1960s. In the mid-1960s virtually all United States acetone was produced from propylene. A process for direct oxidation of propylene to acetone was developed by Wacker Chemie (12), but is not beheved to have been used in the United States. However, by the mid-1970s 60% of United States acetone capacity was based on cumene hydroperoxide [80-15-9], which accounted for about 65% of the acetone produced. 

Although the selectivity of isopropyl alcohol to acetone via vapor-phase dehydrogenation is high, there are a number of by-products that must be removed from the acetone. The hot reactor effluent contains acetone, unconverted isopropyl alcohol, and hydrogen, and may also contain propylene, polypropylene, mesityl oxide, diisopropyl ether, acetaldehyde, propionaldehyde, and many other hydrocarbons and carbon oxides (25,28). 

Aldehydes are important products at all pressures, but at low pressures, acids are not. Carbon monoxide is an important low pressure product and declines with increasing pressure as acids increase. This is evidence for competition between reaction sequence 18—20 and reaction 21. Increasing pressure favors retention of the parent carbon skeleton, in concordance with the reversibiUty of reaction 2. Propylene becomes an insignificant product as the pressure is increased and the temperature is lowered. Both acetone and isopropyl alcohol initially increase as pressure is raised, but acetone passes through a maximum. This increase in the alcohoLcarbonyl ratio is similar to the response of the methanoLformaldehyde ratio when pressure is increased in methane oxidation. 

Diisopropjibenzenes (DIPB) are readily obtained via Eriedel-Crafts alkylation of benzene or cumene by propylene. This reaction inhquid phase has not evolved drastically since 1980 with the exception of the large variety of heterogeneous acid catalysts that are now being used, mainly zeoHtes, type HZSM-12, giving a para/meta ratio = 0.7 (4). In fact, propylene can also be replaced by isopropyl alcohol coming from the hydrogenation of acetone that... 

Aqueous solutions can be stabilized against viscosity loss by addition of 5—10 wt % anhydrous isopropyl alcohol, ethanol, ethylene glycol, or propylene glycol. The manganous ion (Mn " ) also is an effective stabilizer at concentrations of 10 -10 wt% of the solution. 

A second process has two steps. The first step is oxidation of propylene [115-07-1] to acrolein and the second step is reduction of acrolein to ahyl alcohol by a hydrogen transfer reaction, using isopropyl alcohol (25). 

Etherification. Isopropyl alcohol can be dehydrated ia either the Hquid phase over acidic catalysts, eg, sulfuric acid, or ia the vapor phase over acidic aluminas to give diisopropyl ether (DIPE) and propylene (qv). 

The 1990 Clean Air Act mandates for blended oxygenates ia gasoline created a potentially large new use for DIPE as a fuel oxygenate. Isopropyl alcohol can react with propylene over acidic ion-exchange (qv) catalysts at low temperatures, which favor high equiUbrium conversions per pass to produce DIPE (34). 

Glycol ethers can be prepared from isopropyl alcohol by reaction of olefin oxides, eg, ethylene oxide [75-21-8] (qv) or propylene oxide [75-56-9] (qv). Reactions such as that to produce 2-isoproxyethanol [109-59-1] (isopropyl CeUosolve) are generally cataly2ed by an alkaU hydroxide. 

The principal reactions are reversible and a mixture of products and reactants is found in the cmde sulfate. High propylene pressure, high sulfuric acid concentration, and low temperature shift the reaction toward diisopropyl sulfate. However, the reaction rate slows as products are formed, and practical reactors operate by using excess sulfuric acid. As the water content in the sulfuric acid feed is increased, more of the hydrolysis reaction (Step 2) occurs in the main reactor. At water concentrations near 20%, diisopropyl sulfate is not found in the reaction mixture. However, efforts to separate the isopropyl alcohol from the sulfuric acid suggest that it may be partially present in an ionic form (56,57). 

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. 

Wet isopropyl alcohol (87 wt % and 91 vol %) is taken overhead in the second stUl. More than 93% of the charged propylene is converted to isopropyl alcohol in this system. If available, a propylene column may recover unreacted feedstock. 

The bottoms from the stripper (40—60 wt % acid) are sent to an acid reconcentration unit for upgrading to the proper acid strength and recycling to the reactor. Because of the associated high energy requirements, reconcentration of the diluted sulfuric acid is a cosdy operation. However, a propylene gas stripping process, which utilizes only a small amount of added water for hydrolysis, has been described (63). In this modification, the equiUbrium quantity of isopropyl alcohol is stripped so that acid is recycled without reconcentration. Kquilibrium is attained rapidly at 50°C and isopropyl alcohol is removed from the hydrolysis mixture. Similarly, the weak sulfuric acid process minimizes the reconcentration of the acid and its associated corrosion and pollution problems. 

A Hquid-phase variation of the direct hydration was developed by Tokuyama Soda (78). The disadvantages of the gas-phase processes are largely avoided by employing a weakly acidic aqueous catalyst solution of a siHcotungstate (82). Preheated propylene, water, and recycled aqueous catalyst solution are pressurized and fed into a reaction chamber where they react in the Hquid state at 270°C and 20.3 MPa (200 atm) and form aqueous isopropyl alcohol. Propylene conversions of 60—70% per pass are obtained, and selectivity to isopropyl alcohol is 98—99 mol % of converted propylene. The catalyst is recycled and requites Htde replenishment compared to other processes. Corrosion and environmental problems are also minimized because the catalyst is a weak acid and because the system is completely closed. On account of the low gas recycle ratio, regular commercial propylene of 95% purity can be used as feedstock. 

After flashing the propylene, the aqueous solution from the separator is sent to the purification section where the catalyst is separated by a2eotropic distillation 88 wt % isopropyl alcohol is obtained overhead. The bottoms containing aqueous catalyst solution are recycled to the reactor, and the light ends are stripped of low boiling impurities, eg, diisopropyl ether and acetone. A2eotropic distillation yields dry isopropyl alcohol, and the final distillation column yields a product of more than 99.99% purity. 

Price and Demand. In terms of production volume, isopropyl alcohol is about the fourth largest chemical produced from propylene (66). Total 1993 U.S. nameplate capacity for isopropyl alcohol production was 8.48 x 10 metric tons. The total world capacity is about 2.0 x 10 metric tons (Table 4) (126—128). The 1995 U.S. prices were 0.55/L ( 2.10/gal) for refined 91 vol % and 0.62/L ( 2.36/gal) for anhydrous alcohol (129), an increase from the 0.18/L ( 0.70/gal) average price of 1977. The price of isopropyl alcohol is driven by the price of propylene, the primary feedstock, and by the price of ethyl alcohol, a competing solvent. 

Worldwide propylene production and capacity utilization for 1992 are given in Table 6 (74). The world capacity to produce propylene reached 41.5 X 10 t in 1992 the demand for propylene amounted to 32.3 x 10 t. About 80% of propylene produced worldwide was derived from steam crackers the balance came from refinery operations and propylene dehydrogenation. The manufacture of polypropylene, a thermoplastic resin, accounted for about 45% of the total demand. Demand for other uses included manufacture of acrylonitrile (qv), oxochemicals, propylene oxide (qv), cumene (qv), isopropyl alcohol (see Propyl alcohols), and polygas chemicals. Each of these markets accounted for about 5—15% of the propylene demand in 1992 (Table 7). 

The uses of propylene may be loosely categorized as refinery or chemical purpose. In the refinery, propylene occurs in varying concentrations in fuel-gas streams. As a refinery feedstock, propylene is alkylated by isobutane or dimerized to produce polymer gasoHne for gasoHne blending. Commercial chemical derivatives include polypropylene, acrylonitrile, propylene oxide, isopropyl alcohol, and others. In 1992, ca 64% of U.S. propylene suppHes were consumed in the production of chemicals (74). Polypropylene has been the largest consumer of propylene since the early 1970s and is likely to dominate propylene utilization for some time. 

Isopropyl Alcohol. Propylene may be easily hydrolyzed to isopropyl alcohol. Eady commercial processes involved the use of sulfuric acid in an indirect process (100). The disadvantage was the need to reconcentrate the sulfuric acid after hydrolysis. Direct catalytic hydration of propylene to 2-propanol followed commercialization of the sulfuric acid process and eliniinated the need for acid reconcentration, thus reducing corrosion problems, energy use, and air pollution by SO2 and organic sulfur compounds. Gas-phase hydration takes place over supported oxides of tungsten at 540 K and 25... 

A third catalytic route to isopropyl alcohol from propylene involves the use of polytungsten compounds in solution in a Hquid-phase reactor (101). 

Isopropyl Ether. Isopropyl ether is manufactured by the dehydration of isopropyl alcohol with sulfuric acid. It is obtained in large quantities as a by-product in the manufacture of isopropyl alcohol from propylene by the sulfuric acid process, very similar to the production of ethyl ether from ethylene. Isopropyl ether is of moderate importance as an industrial solvent, since its boiling point Hes between that of ethyl ether and acetone. Isopropyl ether very readily forms hazardous peroxides and hydroperoxides, much more so than other ethers. However, this tendency can be controlled with commercial antioxidant additives. Therefore, it is also being promoted as another possible ether to be used in gasoline (33). 

There are two possible structures (isomers) of three carbon atom alcohol. C is n-propyl alcohol (or 1-propanol), the other is isopropyl alcohol (or 2-propanol). The former, no.. ..mufaetured in large quantities is used in printing inks. The latter is manufactured in millions of tons to make propylene by a process similar to that used to convert ethylene to ethanol. The manutaclure of 2-propanol by this process initiated the petrochemical industry in the 1920s. 

Three major non-polymer propylene derivatives are isopropanol, acetone, and acrylic acid. Isopropanol (isopropyl alcohol) is used mainly as a solvent. It has been made from propylene by reaction with sulfuric acid and water for at least the last 75 years, making its manufacture the oldest, still-running commercial organic chemical process. It is used in household rubbing alcohol because, unlike ethanol, it is unfit for human consumption even in small amounts. About 25 % of the isopropanol produced is used for making acetone, in competition with a route based on isopropylbenzene. 

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