Propylene oxide carbon monoxide

The reverse-flow chemical reactor (RFR) has been shown to be a potentially effective technique for many industrial chemical processes, including oxidation of volatile organic compounds such as propane, propylene, and carbon monoxide removal of nitrogen oxides sulfur dioxide oxidation or reduction production of synthesis gas methanol formation and ethylbenzene dehydration into styrene. An excellent introductory article in the topic is given by Eigenberger and Nieken on the effect of the kinetic reaction parameters, reactor size, and operating parameters on RFR performance. A detailed review that summarizes the applications and theory of RFR operation is given by Matros and Bunimovich. 

The reaction is very exothermic. The heat of reaction of propylene oxidation to acrolein is 340.8 kJ /mol (81.5 kcal/mol) the overall reactions generate approximately 837 kJ/mol (200 kcal/mol). The principal side reactions produce acryUc acid, acetaldehyde, acetic acid, carbon monoxide, and carbon dioxide. A variety of other aldehydes and acids are also formed in small amounts. Proprietary processes for acrolein manufacture have been described (25,26). 

The stoichiometric and the catalytic reactions occur simultaneously, but the catalytic reaction predominates. The process is started with stoichiometric amounts, but afterward, carbon monoxide, acetylene, and excess alcohol give most of the acrylate ester by the catalytic reaction. The nickel chloride is recovered and recycled to the nickel carbonyl synthesis step. The main by-product is ethyl propionate, which is difficult to separate from ethyl acrylate. However, by proper control of the feeds and reaction conditions, it is possible to keep the ethyl propionate content below 1%. Even so, this is significantly higher than the propionate content of the esters from the propylene oxidation route. 

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. 

The changeover from ROO radicals to HOO radicals and the switch from organic peroxides to HOOH has been shown as temperature is increased in propane VPO (87,141). Tracer experiments have been used to explore product sequences in propane VPO (142—145). Propylene oxide comes exclusively from propylene. Ethylene, acetaldehyde, formaldehyde, methanol, carbon monoxide, and carbon dioxide come from both propane and propylene. Ethanol comes exclusively from propane. 

Other possible chemical synthesis routes for lactic acid include base-cataly2ed degradation of sugars oxidation of propylene glycol reaction of acetaldehyde, carbon monoxide, and water at elevated temperatures and pressures hydrolysis of chloropropionic acid (prepared by chlorination of propionic acid) nitric acid oxidation of propylene etc. None of these routes has led to a technically and economically viable process (6). 

Nitric acid oxidation is used where carbohydrates, ethylene glycol, and propylene are the starting materials. The diaLkyl oxalate process is the newest, where diaLkyl oxalate is synthesized from carbon monoxide and alcohol, then hydrolyzed to oxahc acid. This process has been developed by UBE Industries in Japan as a CO coupling technology in the course of exploring C-1 chemistry. 

Gas-phase oxidation of propylene using oxygen in the presence of a molten nitrate salt such as sodium nitrate, potassium nitrate, or lithium nitrate and a co-catalyst such as sodium hydroxide results in propylene oxide selectivities greater than 50%. The principal by-products are acetaldehyde, carbon monoxide, carbon dioxide, and acrolein (206—207). This same catalyst system oxidizes propane to propylene oxide and a host of other by-products (208). 

Other important uses of stannic oxide are as a putty powder for polishing marble, granite, glass, and plastic lenses and as a catalyst. The most widely used heterogeneous tin catalysts are those based on binary oxide systems with stannic oxide for use in organic oxidation reactions. The tin—antimony oxide system is particularly selective in the oxidation and ammoxidation of propylene to acrolein, acryHc acid, and acrylonitrile. Research has been conducted for many years on the catalytic properties of stannic oxide and its effectiveness in catalyzing the oxidation of carbon monoxide at below 150°C has been described (25). 

Acetic acid (qv) can be produced synthetically (methanol carbonylation, acetaldehyde oxidation, butane/naphtha oxidation) or from natural sources (5). Oxygen is added to propylene to make acrolein, which is further oxidized to acryHc acid (see Acrylic acid and derivatives). An alternative method adds carbon monoxide and/or water to acetylene (6). Benzoic acid (qv) is made by oxidizing toluene in the presence of a cobalt catalyst (7). 

For example, carbon dioxide from air or ethene nitrogen oxides from nitrogen methanol from diethyl ether. In general, carbon dioxide, carbon monoxide, ammonia, hydrogen sulfide, mercaptans, ethane, ethene, acetylene (ethyne), propane and propylene are readily removed at 25°. In mixtures of gases, the more polar ones are preferentially adsorbed). 

Compounds considered carcinogenic that may be present in air emissions include benzene, butadiene, 1,2-dichloroethane, and vinyl chloride. A typical naphtha cracker at a petrochemical complex may release annually about 2,500 metric tons of alkenes, such as propylenes and ethylene, in producing 500,000 metric tons of ethylene. Boilers, process heaters, flares, and other process equipment (which in some cases may include catalyst regenerators) are responsible for the emission of PM (particulate matter), carbon monoxide, nitrogen oxides (200 tpy), based on 500,000 tpy of ethylene capacity, and sulfur oxides (600 tpy). 

From the results of other authors should be mentioned the observation of a similar effect, e.g. in the oxidation of olefins on nickel oxide (118), where the retardation of the reaction of 1-butene by cis-2-butene was greater than the effect of 1-butene on the reaction of m-2-butene the ratio of the adsorption coefficients Kcia h/Kwas 1.45. In a study on hydrogenation over C03O4 it was reported (109) that the reactivities of ethylene and propylene were nearly the same (1.17 in favor of propylene), when measured separately, whereas the ratio of adsorption coefficients was 8.4 in favor of ethylene. This led in the competitive arrangement to preferential hydrogenation of ethylene. A similar phenomenon occurs in the catalytic reduction of nitric oxide and sulfur dioxide by carbon monoxide (120a). 

A sophisticated quantitative analysis of experimental data was performed by Voltz et al. (96). Their experiment was performed over commercially available platinum catalysts on pellets and monoliths, with temperatures and gaseous compositions simulating exhaust gases. They found that carbon monoxide, propylene, and nitric oxide all exhibit strong poisoning effects on all kinetic rates. Their data can be fitted by equations of the form ... 

The formation of polyesters from carbon monoxide and propylene oxide using a cobalt catalyst may involve an alternate coordination on the metal and an insertion of monomers into the carbon-transition metal bond240. ... 

Acrolein is immediately passed through a second oxidation reactor to form acrylic acid. The reaction talces place at 475-575 E, over a tin-antimony oxide catalyst. A few by-products form, namely, formic acid (HCOOH), acetic acid (CH3COOH), low molecular weight polymers, carbon monoxide, and dioxide. But overall yields of propylene to acrylic acid are high—85 to 90%. 

Some acrylates are still produced by a modified Reppe process that involves the reaction of acetylene, the appropriate alcohol (in the case of butyl acrylate, butyl alcohol is used), and carbon monoxide in the presence of an acid. The process is continuous and a small amount of acrylates is made this way. The most economical method of acrylate production is that of the direct oxidation of propylene to acrylic acid, followed by esterification. 

From a retrosynthetic point of view, propylene oxide (PO) and carbon monoxide (CO) are promising building blocks for the production of low-cost PHB (Fig. 13). 

In 1963, Heck reported the ring opening of propylene oxide by the carbonylating reagent tetracarbonylhydridocobalt(I) in the presence of carbon monoxide, which results in a stable acyl cobalttetracarbonyl compound (Fig. 15). However, no polymeric products were reported, which would result from multiple ring opening and CO insertion processes [58, 59]. 

Contrary to the ionic mechanism suggested by Tsuji, an insertion mechanism explains the facts much better. An external attack of carbon monoxide at the most positive carbon atom of propylene in a palladium chloride complex, as Tsuji proposed, would be expected to produce 3-chloro-2-methylpropionyl chloride rather than the observed product, 3-chlorobutyryl chloride. Since oxidation of propylene by Pd (II) ion gives acetone rather than propionalydehyde, a CO insertion reaction and elimination should produce the observed compound, 3-chlorobutyryl chloride... 

The use of equation (3.2) to study the behaviour of catalysts is known as solid electrolyte potentiometry (SEP). Wagner38 was the first to put forward the idea of using SEP to study catalysts under working conditions. Vayenas and Saltsburg were the first to apply the technique to the fundamental study of a catalytic reaction for the case of the oxidation of sulfur dioxide.39 Since then the technique has been widely used, with particular success in the study of periodic and oscillatory phenomena for such reactions as the oxidation of carbon monoxide on platinum, hydrogen on nickel, ethylene on platinum and propylene oxide on silver. 

The detection of 1,2-propylene oxide in the products from methyl ethyl ketone combustion is particularly interesting. It parallels the formation of ethylene oxide in acetone combustion (8) and of 1,2-butylene oxide in the combustion of diethyl ketone. Thus, there is apparently a group of isomerization reactions in which carbon monoxide is ejected from the transition state with subsequent closing of the C—C bond. Examination of scale molecular models shows that reactions of this type are, at any rate, plausible geometrically. 

Oxygen-containing by-products such as methanol, formaldehyde, and propylene oxide were also found. Although the ultimate products are water and carbon dioxide, here the amount of carbon dioxide was less than one-tenth that of carbon monoxide. 

The optimum residence times are to be 11-12 sec. for 400°C., 8-10 sec. for 430°C., 6-7 sec. for 450°C. and 4-6 sec. for 480°C. Carbon monoxide, methanol, formaldehyde, and acetone are decreased with the increase in reaction temperature. At 480°C. the yield of carbon monoxide is a little less and that of propylene oxide is more than those at the other temperatures because of the smaller content of oxygen in the feed gas. 

In hydrocarbons a variety of by-products was formed. Propylene oxide gave some j8-hydroxyisobutyraldehyde as well as the normal product, also acetone, isobutyraldehyde, methacrolein, n-butyraldehyde, isobutanol, crotonaldehyde, and n-butanol. Presumably these by-products were formed by dehydration and hydrogenation of the hydroxyaldehydes, except for acetone which was formed by isomerization. The side reactions can be kept to a minimum by operating below 95° C (160). Fewer by-products appear to be formed using alcohols as solvents. Using methanol, Eisenmann (24) noted that carbon monoxide had an inhibitory effect at high pressures. 

PMMA PNGV PO POx PPMA PrOx PTFE PVD PZT Poly-methylmethacrylate Partnership of New Generation Vehicles Propylene oxide Partial oxidation Poly-methyl methacrylate Preferential carbon monoxide oxidation Poly-tetrafluorethylene Physical vapor deposition Lead-zirconate-titanate... 

Acrylic Acid, Acrylates, and Acrylonitrile. Acrylic acid [79-10-7], C3H402, and acrylates were once prepared by reaction of acetylene and carbon monoxide with water or an alcohol, using nickel carbonyl as catalyst. I11 recent years tliis process has been completely superseded in the United States by newer processes involving oxidation of propylene (2). I11 western Europe, however, acetylene is still important in acrylate manufacture (see Acrylic acid and derivatives Acrylic ester polymers). 

---