US20040054235A1 - Process for oxidation of cyclohexane - Google Patents
Process for oxidation of cyclohexane Download PDFInfo
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- US20040054235A1 US20040054235A1 US10/242,544 US24254402A US2004054235A1 US 20040054235 A1 US20040054235 A1 US 20040054235A1 US 24254402 A US24254402 A US 24254402A US 2004054235 A1 US2004054235 A1 US 2004054235A1
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- process according
- phase
- decomposition
- cyclohexanol
- cyclohexanone
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- 238000000034 method Methods 0.000 title claims abstract description 37
- XDTMQSROBMDMFD-UHFFFAOYSA-N Cyclohexane Chemical compound C1CCCCC1 XDTMQSROBMDMFD-UHFFFAOYSA-N 0.000 title claims abstract description 17
- 230000003647 oxidation Effects 0.000 title claims abstract description 11
- 238000007254 oxidation reaction Methods 0.000 title claims abstract description 11
- JHIVVAPYMSGYDF-UHFFFAOYSA-N cyclohexanone Chemical compound O=C1CCCCC1 JHIVVAPYMSGYDF-UHFFFAOYSA-N 0.000 claims abstract description 24
- FGGJBCRKSVGDPO-UHFFFAOYSA-N hydroperoxycyclohexane Chemical group OOC1CCCCC1 FGGJBCRKSVGDPO-UHFFFAOYSA-N 0.000 claims abstract description 22
- 238000000354 decomposition reaction Methods 0.000 claims abstract description 14
- HPXRVTGHNJAIIH-UHFFFAOYSA-N cyclohexanol Chemical compound OC1CCCCC1 HPXRVTGHNJAIIH-UHFFFAOYSA-N 0.000 claims abstract description 13
- 239000000203 mixture Substances 0.000 claims abstract description 12
- 238000004519 manufacturing process Methods 0.000 claims abstract description 6
- 239000011651 chromium Substances 0.000 claims description 24
- VYZAMTAEIAYCRO-UHFFFAOYSA-N Chromium Chemical compound [Cr] VYZAMTAEIAYCRO-UHFFFAOYSA-N 0.000 claims description 15
- 229910052804 chromium Inorganic materials 0.000 claims description 15
- 239000012071 phase Substances 0.000 claims description 14
- XLYOFNOQVPJJNP-UHFFFAOYSA-N water Substances O XLYOFNOQVPJJNP-UHFFFAOYSA-N 0.000 claims description 12
- WNLRTRBMVRJNCN-UHFFFAOYSA-N adipic acid Chemical compound OC(=O)CCCCC(O)=O WNLRTRBMVRJNCN-UHFFFAOYSA-N 0.000 claims description 8
- 239000006227 byproduct Substances 0.000 claims description 8
- 239000003054 catalyst Substances 0.000 claims description 8
- 239000012074 organic phase Substances 0.000 claims description 8
- 238000004821 distillation Methods 0.000 claims description 7
- 239000008346 aqueous phase Substances 0.000 claims description 6
- 239000008151 electrolyte solution Substances 0.000 claims description 6
- 239000000047 product Substances 0.000 claims description 5
- 238000007670 refining Methods 0.000 claims description 5
- 239000001361 adipic acid Substances 0.000 claims description 4
- 235000011037 adipic acid Nutrition 0.000 claims description 4
- 239000003518 caustics Substances 0.000 claims description 3
- 229910052737 gold Inorganic materials 0.000 claims description 3
- 229910052751 metal Inorganic materials 0.000 claims description 3
- 239000002184 metal Substances 0.000 claims description 3
- 230000001590 oxidative effect Effects 0.000 claims description 3
- 238000000926 separation method Methods 0.000 claims description 3
- 239000000243 solution Substances 0.000 claims description 3
- 238000005979 thermal decomposition reaction Methods 0.000 claims description 3
- 238000003421 catalytic decomposition reaction Methods 0.000 claims description 2
- 238000009903 catalytic hydrogenation reaction Methods 0.000 claims description 2
- 238000011084 recovery Methods 0.000 claims description 2
- 150000007513 acids Chemical class 0.000 claims 1
- 229910052763 palladium Inorganic materials 0.000 claims 1
- 239000007800 oxidant agent Substances 0.000 description 8
- QTBSBXVTEAMEQO-UHFFFAOYSA-N Acetic acid Chemical compound CC(O)=O QTBSBXVTEAMEQO-UHFFFAOYSA-N 0.000 description 3
- HEMHJVSKTPXQMS-UHFFFAOYSA-M Sodium hydroxide Chemical compound [OH-].[Na+] HEMHJVSKTPXQMS-UHFFFAOYSA-M 0.000 description 3
- 238000000605 extraction Methods 0.000 description 3
- 239000007789 gas Substances 0.000 description 3
- 230000007062 hydrolysis Effects 0.000 description 3
- 238000006460 hydrolysis reaction Methods 0.000 description 3
- 239000000463 material Substances 0.000 description 3
- FERIUCNNQQJTOY-UHFFFAOYSA-N Butyric acid Chemical compound CCCC(O)=O FERIUCNNQQJTOY-UHFFFAOYSA-N 0.000 description 2
- OAKJQQAXSVQMHS-UHFFFAOYSA-N Hydrazine Chemical compound NN OAKJQQAXSVQMHS-UHFFFAOYSA-N 0.000 description 2
- KDLHZDBZIXYQEI-UHFFFAOYSA-N Palladium Chemical compound [Pd] KDLHZDBZIXYQEI-UHFFFAOYSA-N 0.000 description 2
- VYPSYNLAJGMNEJ-UHFFFAOYSA-N Silicium dioxide Chemical compound O=[Si]=O VYPSYNLAJGMNEJ-UHFFFAOYSA-N 0.000 description 2
- 239000002253 acid Substances 0.000 description 2
- 238000010306 acid treatment Methods 0.000 description 2
- 239000003929 acidic solution Substances 0.000 description 2
- 239000000654 additive Substances 0.000 description 2
- PNEYBMLMFCGWSK-UHFFFAOYSA-N aluminium oxide Inorganic materials [O-2].[O-2].[O-2].[Al+3].[Al+3] PNEYBMLMFCGWSK-UHFFFAOYSA-N 0.000 description 2
- 239000007795 chemical reaction product Substances 0.000 description 2
- JOPOVCBBYLSVDA-UHFFFAOYSA-N chromium(6+) Chemical compound [Cr+6] JOPOVCBBYLSVDA-UHFFFAOYSA-N 0.000 description 2
- 238000002485 combustion reaction Methods 0.000 description 2
- 238000005260 corrosion Methods 0.000 description 2
- 230000007797 corrosion Effects 0.000 description 2
- 230000007613 environmental effect Effects 0.000 description 2
- 239000000446 fuel Substances 0.000 description 2
- PCHJSUWPFVWCPO-UHFFFAOYSA-N gold Chemical compound [Au] PCHJSUWPFVWCPO-UHFFFAOYSA-N 0.000 description 2
- 239000010931 gold Substances 0.000 description 2
- 239000002638 heterogeneous catalyst Substances 0.000 description 2
- FUZZWVXGSFPDMH-UHFFFAOYSA-N hexanoic acid Chemical compound CCCCCC(O)=O FUZZWVXGSFPDMH-UHFFFAOYSA-N 0.000 description 2
- 238000005984 hydrogenation reaction Methods 0.000 description 2
- 239000012535 impurity Substances 0.000 description 2
- BDAGIHXWWSANSR-UHFFFAOYSA-N methanoic acid Natural products OC=O BDAGIHXWWSANSR-UHFFFAOYSA-N 0.000 description 2
- NQPDZGIKBAWPEJ-UHFFFAOYSA-N valeric acid Chemical compound CCCCC(O)=O NQPDZGIKBAWPEJ-UHFFFAOYSA-N 0.000 description 2
- RTBFRGCFXZNCOE-UHFFFAOYSA-N 1-methylsulfonylpiperidin-4-one Chemical compound CS(=O)(=O)N1CCC(=O)CC1 RTBFRGCFXZNCOE-UHFFFAOYSA-N 0.000 description 1
- OSWFIVFLDKOXQC-UHFFFAOYSA-N 4-(3-methoxyphenyl)aniline Chemical compound COC1=CC=CC(C=2C=CC(N)=CC=2)=C1 OSWFIVFLDKOXQC-UHFFFAOYSA-N 0.000 description 1
- IWHLYPDWHHPVAA-UHFFFAOYSA-N 6-hydroxyhexanoic acid Chemical compound OCCCCCC(O)=O IWHLYPDWHHPVAA-UHFFFAOYSA-N 0.000 description 1
- UFHFLCQGNIYNRP-UHFFFAOYSA-N Hydrogen Chemical compound [H][H] UFHFLCQGNIYNRP-UHFFFAOYSA-N 0.000 description 1
- GRYLNZFGIOXLOG-UHFFFAOYSA-N Nitric acid Chemical compound O[N+]([O-])=O GRYLNZFGIOXLOG-UHFFFAOYSA-N 0.000 description 1
- 239000004677 Nylon Substances 0.000 description 1
- KDYFGRWQOYBRFD-UHFFFAOYSA-N Succinic acid Natural products OC(=O)CCC(O)=O KDYFGRWQOYBRFD-UHFFFAOYSA-N 0.000 description 1
- 229910000147 aluminium phosphate Inorganic materials 0.000 description 1
- JFCQEDHGNNZCLN-UHFFFAOYSA-N anhydrous glutaric acid Natural products OC(=O)CCCC(O)=O JFCQEDHGNNZCLN-UHFFFAOYSA-N 0.000 description 1
- 239000007864 aqueous solution Substances 0.000 description 1
- RQPZNWPYLFFXCP-UHFFFAOYSA-L barium dihydroxide Chemical compound [OH-].[OH-].[Ba+2] RQPZNWPYLFFXCP-UHFFFAOYSA-L 0.000 description 1
- 229910001863 barium hydroxide Inorganic materials 0.000 description 1
- 230000009286 beneficial effect Effects 0.000 description 1
- KDYFGRWQOYBRFD-NUQCWPJISA-N butanedioic acid Chemical compound O[14C](=O)CC[14C](O)=O KDYFGRWQOYBRFD-NUQCWPJISA-N 0.000 description 1
- AXCZMVOFGPJBDE-UHFFFAOYSA-L calcium dihydroxide Chemical compound [OH-].[OH-].[Ca+2] AXCZMVOFGPJBDE-UHFFFAOYSA-L 0.000 description 1
- 239000000920 calcium hydroxide Substances 0.000 description 1
- 229910001861 calcium hydroxide Inorganic materials 0.000 description 1
- 230000003197 catalytic effect Effects 0.000 description 1
- 150000001844 chromium Chemical class 0.000 description 1
- RPBPCPJJHKASGQ-UHFFFAOYSA-K chromium(3+);octanoate Chemical compound [Cr+3].CCCCCCCC([O-])=O.CCCCCCCC([O-])=O.CCCCCCCC([O-])=O RPBPCPJJHKASGQ-UHFFFAOYSA-K 0.000 description 1
- 229910017052 cobalt Inorganic materials 0.000 description 1
- 239000010941 cobalt Substances 0.000 description 1
- GUTLYIVDDKVIGB-UHFFFAOYSA-N cobalt atom Chemical compound [Co] GUTLYIVDDKVIGB-UHFFFAOYSA-N 0.000 description 1
- 229910052802 copper Inorganic materials 0.000 description 1
- 230000009849 deactivation Effects 0.000 description 1
- 239000006185 dispersion Substances 0.000 description 1
- 230000008030 elimination Effects 0.000 description 1
- 238000003379 elimination reaction Methods 0.000 description 1
- 238000001704 evaporation Methods 0.000 description 1
- 230000008020 evaporation Effects 0.000 description 1
- 239000002778 food additive Substances 0.000 description 1
- 235000013373 food additive Nutrition 0.000 description 1
- 235000019253 formic acid Nutrition 0.000 description 1
- 229910001385 heavy metal Inorganic materials 0.000 description 1
- 239000001257 hydrogen Substances 0.000 description 1
- 229910052739 hydrogen Inorganic materials 0.000 description 1
- 239000007788 liquid Substances 0.000 description 1
- 150000002736 metal compounds Chemical group 0.000 description 1
- 150000002739 metals Chemical class 0.000 description 1
- 229910017604 nitric acid Inorganic materials 0.000 description 1
- 229920001778 nylon Polymers 0.000 description 1
- 239000000546 pharmaceutical excipient Substances 0.000 description 1
- NBIIXXVUZAFLBC-UHFFFAOYSA-N phosphoric acid Substances OP(O)(O)=O NBIIXXVUZAFLBC-UHFFFAOYSA-N 0.000 description 1
- -1 phosphoric acid organic esters Chemical class 0.000 description 1
- 238000007747 plating Methods 0.000 description 1
- 239000004814 polyurethane Substances 0.000 description 1
- 229920002635 polyurethane Polymers 0.000 description 1
- 230000001376 precipitating effect Effects 0.000 description 1
- 239000000377 silicon dioxide Substances 0.000 description 1
- 239000010802 sludge Substances 0.000 description 1
- 229910001220 stainless steel Inorganic materials 0.000 description 1
- 239000010935 stainless steel Substances 0.000 description 1
- 238000001256 steam distillation Methods 0.000 description 1
- 238000010977 unit operation Methods 0.000 description 1
- 238000005292 vacuum distillation Methods 0.000 description 1
- 229940005605 valeric acid Drugs 0.000 description 1
- 239000011345 viscous material Substances 0.000 description 1
- 238000005406 washing Methods 0.000 description 1
- 239000002699 waste material Substances 0.000 description 1
Images
Classifications
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- C—CHEMISTRY; METALLURGY
- C07—ORGANIC CHEMISTRY
- C07C—ACYCLIC OR CARBOCYCLIC COMPOUNDS
- C07C29/00—Preparation of compounds having hydroxy or O-metal groups bound to a carbon atom not belonging to a six-membered aromatic ring
- C07C29/132—Preparation of compounds having hydroxy or O-metal groups bound to a carbon atom not belonging to a six-membered aromatic ring by reduction of an oxygen containing functional group
-
- C—CHEMISTRY; METALLURGY
- C07—ORGANIC CHEMISTRY
- C07C—ACYCLIC OR CARBOCYCLIC COMPOUNDS
- C07C29/00—Preparation of compounds having hydroxy or O-metal groups bound to a carbon atom not belonging to a six-membered aromatic ring
- C07C29/74—Separation; Purification; Use of additives, e.g. for stabilisation
- C07C29/76—Separation; Purification; Use of additives, e.g. for stabilisation by physical treatment
- C07C29/80—Separation; Purification; Use of additives, e.g. for stabilisation by physical treatment by distillation
-
- C—CHEMISTRY; METALLURGY
- C07—ORGANIC CHEMISTRY
- C07C—ACYCLIC OR CARBOCYCLIC COMPOUNDS
- C07C407/00—Preparation of peroxy compounds
-
- C—CHEMISTRY; METALLURGY
- C07—ORGANIC CHEMISTRY
- C07C—ACYCLIC OR CARBOCYCLIC COMPOUNDS
- C07C407/00—Preparation of peroxy compounds
- C07C407/003—Separation; Purification; Stabilisation; Use of additives
-
- C—CHEMISTRY; METALLURGY
- C07—ORGANIC CHEMISTRY
- C07C—ACYCLIC OR CARBOCYCLIC COMPOUNDS
- C07C409/00—Peroxy compounds
- C07C409/02—Peroxy compounds the —O—O— group being bound between a carbon atom, not further substituted by oxygen atoms, and hydrogen, i.e. hydroperoxides
- C07C409/14—Peroxy compounds the —O—O— group being bound between a carbon atom, not further substituted by oxygen atoms, and hydrogen, i.e. hydroperoxides the carbon atom belonging to a ring other than a six-membered aromatic ring
-
- C—CHEMISTRY; METALLURGY
- C07—ORGANIC CHEMISTRY
- C07C—ACYCLIC OR CARBOCYCLIC COMPOUNDS
- C07C45/00—Preparation of compounds having >C = O groups bound only to carbon or hydrogen atoms; Preparation of chelates of such compounds
- C07C45/27—Preparation of compounds having >C = O groups bound only to carbon or hydrogen atoms; Preparation of chelates of such compounds by oxidation
-
- C—CHEMISTRY; METALLURGY
- C07—ORGANIC CHEMISTRY
- C07C—ACYCLIC OR CARBOCYCLIC COMPOUNDS
- C07C45/00—Preparation of compounds having >C = O groups bound only to carbon or hydrogen atoms; Preparation of chelates of such compounds
- C07C45/27—Preparation of compounds having >C = O groups bound only to carbon or hydrogen atoms; Preparation of chelates of such compounds by oxidation
- C07C45/32—Preparation of compounds having >C = O groups bound only to carbon or hydrogen atoms; Preparation of chelates of such compounds by oxidation with molecular oxygen
- C07C45/33—Preparation of compounds having >C = O groups bound only to carbon or hydrogen atoms; Preparation of chelates of such compounds by oxidation with molecular oxygen of CHx-moieties
-
- C—CHEMISTRY; METALLURGY
- C07—ORGANIC CHEMISTRY
- C07C—ACYCLIC OR CARBOCYCLIC COMPOUNDS
- C07C45/00—Preparation of compounds having >C = O groups bound only to carbon or hydrogen atoms; Preparation of chelates of such compounds
- C07C45/51—Preparation of compounds having >C = O groups bound only to carbon or hydrogen atoms; Preparation of chelates of such compounds by pyrolysis, rearrangement or decomposition
- C07C45/53—Preparation of compounds having >C = O groups bound only to carbon or hydrogen atoms; Preparation of chelates of such compounds by pyrolysis, rearrangement or decomposition of hydroperoxides
-
- C—CHEMISTRY; METALLURGY
- C07—ORGANIC CHEMISTRY
- C07C—ACYCLIC OR CARBOCYCLIC COMPOUNDS
- C07C45/00—Preparation of compounds having >C = O groups bound only to carbon or hydrogen atoms; Preparation of chelates of such compounds
- C07C45/78—Separation; Purification; Stabilisation; Use of additives
-
- C—CHEMISTRY; METALLURGY
- C07—ORGANIC CHEMISTRY
- C07C—ACYCLIC OR CARBOCYCLIC COMPOUNDS
- C07C45/00—Preparation of compounds having >C = O groups bound only to carbon or hydrogen atoms; Preparation of chelates of such compounds
- C07C45/78—Separation; Purification; Stabilisation; Use of additives
- C07C45/81—Separation; Purification; Stabilisation; Use of additives by change in the physical state, e.g. crystallisation
- C07C45/82—Separation; Purification; Stabilisation; Use of additives by change in the physical state, e.g. crystallisation by distillation
-
- C—CHEMISTRY; METALLURGY
- C07—ORGANIC CHEMISTRY
- C07C—ACYCLIC OR CARBOCYCLIC COMPOUNDS
- C07C2601/00—Systems containing only non-condensed rings
- C07C2601/12—Systems containing only non-condensed rings with a six-membered ring
- C07C2601/14—The ring being saturated
Definitions
- the present invention relates to a process for the production of cyclohexanol, cyclohexanone and cyclohexyl hydroperoxide from a cyclohexane oxidation process.
- Oxidation of cyclohexane by air produces a reaction product comprising cyclohexanol (A), cyclohexanone (K) cyclohexyl-hydroperoxide (CHHP) and small amounts of by-products.
- the reaction product is treated with water followed by separation of organic and aqueous phases.
- the organic phase comprising A, K and CHHP is further treated to cause decomposition of CHHP to K and A. Therefore, K and A are the main product of the overall process, their mixture is commonly known as “KA-oil”.
- KA oil is produced from crude KA oil by distillation. All the byproducts, catalysts, additives, corrosion derived metal compounds form what is referred to as the “tails” of the distillation column (U.S. Pat. No. 4,720,592).
- the KA oil is distilled in the final step.
- the material that remains after the KA distillation is a viscous material, usually dark in color, comprising the impurities formed during the process, the non-volatile catalysts, and any additives that were used in the process.
- Non Volatile Residue or “NVR”.
- the tails stream is often concentrated through evaporation.
- the concentrated stream commonly known as non-volatile residue (NVR) is often disposed of as boiler fuel.
- the NVR is an aqueous dispersion.
- the composition comprises formic acid, acetic acid, butyric acid, valeric acid, caproic acid, 6-hydroxycaproic acid, succinic acid, glutaric acid, adipic acid, phosphoric acid organic esters, chromium salts, and other materials.
- the amount of NVR formed during KA production is significant, it may represent up to 20% of the amount of KA oil produced and normally it is disposed by burning and getting credit for the fuel value. Because of more demanding environmental regulations the disposal of NVR with high chromium content by burning in boilers will be unacceptable.
- the object of the present invention is to provide a method for producing KA oil and having NVR by-product with low Cr concentration.
- FIG. 1 is a schematic flow chart of the process of the present invention, and is provided to aid in the understanding of the process.
- the Air oxidizer ( 1 ) is used to oxidize the cyclohexane.
- the water separator ( 2 ) is used to collect the aqueous phase that results from step 1 of the present process.
- Cyclohexyl hydroperoxide that is present in a second phase is decomposed in a CHHP decomposition reactor ( 3 ) to cyclohexanone and cyclohexanol. These products are distilled in a distillation column ( 4 ) and then KA refined in a refiner ( 5 ).
- the NVR that remains in the refiner ( 5 ) is then contacted with first, either a dilute acid ( 6 ) or with an aqueous electrolyte solution ( 7 ) to extract chromium. Finally, a phase separator ( 8 ) is used to separate the chromium into the aqueous phase.
- Cyclohexane is air oxidized in a tower oxidizer ( 1 ) and the oxidizer tails are contacted with water.
- the water is separated in a decanter ( 2 ) into a first phase and second phase.
- the first phase comprising substantially aqueous (water-soluble) components and said second phase comprising cyclohexanol and organic components.
- the water washed organic phase is directed to the CHHP decomposition reactor ( 3 ) where it is treated with chromium octoate and is decomposed in K and A.
- the cyclohexane is recovered by distillation ( 4 ) and recycled.
- the resulting crude KA oil is refined in the KA refiner ( 5 ) and the KA is distilled of at the top of the column.
- the NVR is collected at the bottom of refining column.
- the resulted NVR is contacted with an acidic solution in the acid treatment reactor ( 6 ).
- the non-volatile residue is further contacted with an electrolyte solution ( 7 ), followed by separation of the aqueous phase from the organic phase ( 8 ).
- the separated organic phase is the NVR with low Cr concentration ( ⁇ 2 ppm).
- a process for the production of cyclohexanone and cyclohexanol mixture from cyclohexane together with byproduct recovery comprising: (i) oxidizing cyclohexane to obtain air oxidation tails; (ii) contacting the air oxidation tails with water; (iii) separating the mixture resulting from step (ii) into a first phase and a second phase, said first phase comprising substantially aqueous components and said second phase comprising cyclohexyl hydroperoxide and organic components; (iv) decomposing the cyclohexyl hydroperoxide in the organic phase from step (iii) to cyclohexanone and cyclohexanol; (v) refining of the cyclohexanol and cyclohexanone mixture obtained in step (iv) and (vi) separating chromium from nonvolatile residue.
- the cyclohexane is contacted with air in the air oxidizer ( 1 ) at temperatures between about 100° C. to about 175° C.
- the air oxidizer can be an oxidation tower, stirred or non-stirred tank reactor(s), stirred or non-stirred autoclave(s).
- the air oxidizer tails are contacted with water. The ratio between the air oxidizer tails and water is about 100:1.
- the cyclohexyl-hydroperoxide is decomposed to K and A ( 3 ).
- Decomposition of the CHHP may be accomplished using thermal decomposition, catalytic decomposition, catalytic hydrogenation or other catalytic methods such as the use of gold catalyst, for example.
- Thermal decomposition is carried out at relatively high temperatures, 120-175° C. and long hold-up times.
- CHHP hydrogenation is carried out with heterogeneous catalysts, at temperatures between about 100 to about 160° C.
- Hydrogenation catalysts include but not limited to palladium on silica or alumina support.
- CHHP decomposition may also be accomplished without hydrogen with the use of different heterogeneous catalysts such as gold deposited on silica or alumina at temperatures between 100-160° C.
- CHHP decomposition may also be accomplished by metal catalyzed decomposition in caustic aqueous solution. This is done by contacting the CHHP with cobalt, chromium, or a mixture thereof, in caustic solutions, preferably sodium hydroxide. When using either or both of these metals for CHHP decomposition the concentration of Co and/or Cr is between 0.1 and 20 ppm.
- the excess cyclohexane is distilled off ( 4 ) and the resulting KA oil is distilled in KA Refiner at temperatures between from about 90 to about 170° C. ( 5 ).
- Some of the process steps, such as water washing the AOR tails, are beneficial in reducing deactivation of the catalyst but are not essential.
- the cyclohexane distillation and KA oil refining can be performed by different unit operations such as vacuum distillation, steam distillation, etc.
- the NVR remaining in the bottom of the KA Refiner column ( 5 ) is sent to acid treatment reactor ( 6 ).
- the NVR is contacted in ( 6 ) with diluted acid solutions (0.2-10%) at temperatures between about 60 to about 120° C.
- the NVR is contacted with an aqueous electrolyte solution ( 7 ) to extract the Cr into the aqueous layer.
- the extraction step of the Cr in aqueous electrolyte solution can be accomplished at temperatures between about 20 to about 0120° C.
- the NVR with reduced Cr is separated from the aqueous electrolyte solution in a decanter ( 8 ).
- the extraction and hydrolysis steps may need to be repeated in order to reduce the Cr to very low levels.
- the hydrolysis and extraction steps can be reversed in order.
- the K and A is obtained as a mixture.
- the product (K and A) is oxidized to produce adipic acid.
- the oxidizing agent that may be used is nitric acid.
- the resulting adipic acid may be used in turn to make Nylon products, pharmaceutical additives, food additives, polyurethane, and a host of other applications.
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- Organic Low-Molecular-Weight Compounds And Preparation Thereof (AREA)
- Low-Molecular Organic Synthesis Reactions Using Catalysts (AREA)
Abstract
Description
- The present invention relates to a process for the production of cyclohexanol, cyclohexanone and cyclohexyl hydroperoxide from a cyclohexane oxidation process.
- Oxidation of cyclohexane by air produces a reaction product comprising cyclohexanol (A), cyclohexanone (K) cyclohexyl-hydroperoxide (CHHP) and small amounts of by-products. The reaction product is treated with water followed by separation of organic and aqueous phases. The organic phase comprising A, K and CHHP is further treated to cause decomposition of CHHP to K and A. Therefore, K and A are the main product of the overall process, their mixture is commonly known as “KA-oil”.
- Several byproducts formed during the above processes remain as impurities mixed with KA oil (crude) along with unreacted cyclohexane. Refined KA oil is produced from crude KA oil by distillation. All the byproducts, catalysts, additives, corrosion derived metal compounds form what is referred to as the “tails” of the distillation column (U.S. Pat. No. 4,720,592). In order to eliminate the by-products produced during the process, the KA oil is distilled in the final step. The material that remains after the KA distillation is a viscous material, usually dark in color, comprising the impurities formed during the process, the non-volatile catalysts, and any additives that were used in the process. Collectively these materials are referred to as “Non Volatile Residue” or “NVR”). The tails stream is often concentrated through evaporation. The concentrated stream, commonly known as non-volatile residue (NVR) is often disposed of as boiler fuel.
- Corrosion in process vessels made of stainless steel adds chromium to NVR. In addition, for a CHHP decomposition process using chromium catalyst (U.S. Pat. No. 4,465,861), the chromium ends up in the NVR. Typically, a concentration of chromium in the range of 2-100 ppm is observed in NVR. Upon combustion in a boiler, the chromium forms a part of the emission through boiler stack gas. In order to comply with environmental regulations, the stack gas needs expensive treatment for chromium reduction. Alternative routes to disposal of NVR are also expensive.
- It is, therefore, desirable to have process of oxidation of cyclohexane to produce KA oil, the said process comprising one or more steps to reduce chromium content of NVR so the stack gas corresponding to its combustion will contain an acceptable low concentration of chromium.
- The NVR is an aqueous dispersion. Typically, the composition comprises formic acid, acetic acid, butyric acid, valeric acid, caproic acid, 6-hydroxycaproic acid, succinic acid, glutaric acid, adipic acid, phosphoric acid organic esters, chromium salts, and other materials.
- The amount of NVR formed during KA production is significant, it may represent up to 20% of the amount of KA oil produced and normally it is disposed by burning and getting credit for the fuel value. Because of more demanding environmental regulations the disposal of NVR with high chromium content by burning in boilers will be unacceptable.
- There are known procedures to eliminate hexavalent chromium from heavy metal sludge or waste liquid, involving reducing the hexavalent chromium in acidic solution to trivalent (JP 2001058192 A 20010306). This procedure is not applicable for Cr elimination from NVR because all the NVR will be solubilized during treatment in water.
- There are also treatment systems available to eliminate chromium from plating operations (U.S. Pat. No. 5,932,109) by precipitating using hydrazine or Al and Cu shavings (RU 2,023,674) by adding calcium hydroxide to specified pH value then barium hydroxide to further increase pH (SU 1323537).
- The object of the present invention is to provide a method for producing KA oil and having NVR by-product with low Cr concentration.
- FIG. 1 is a schematic flow chart of the process of the present invention, and is provided to aid in the understanding of the process. The Air oxidizer ( 1) is used to oxidize the cyclohexane. The water separator (2) is used to collect the aqueous phase that results from
step 1 of the present process. Cyclohexyl hydroperoxide that is present in a second phase is decomposed in a CHHP decomposition reactor (3) to cyclohexanone and cyclohexanol. These products are distilled in a distillation column (4) and then KA refined in a refiner (5). The NVR that remains in the refiner (5) is then contacted with first, either a dilute acid (6) or with an aqueous electrolyte solution (7) to extract chromium. Finally, a phase separator (8) is used to separate the chromium into the aqueous phase. - Cyclohexane is air oxidized in a tower oxidizer ( 1) and the oxidizer tails are contacted with water. The water is separated in a decanter (2) into a first phase and second phase. The first phase comprising substantially aqueous (water-soluble) components and said second phase comprising cyclohexanol and organic components. The water washed organic phase is directed to the CHHP decomposition reactor (3) where it is treated with chromium octoate and is decomposed in K and A. The cyclohexane is recovered by distillation (4) and recycled. The resulting crude KA oil is refined in the KA refiner (5) and the KA is distilled of at the top of the column. The NVR is collected at the bottom of refining column. The resulted NVR is contacted with an acidic solution in the acid treatment reactor (6). The non-volatile residue is further contacted with an electrolyte solution (7), followed by separation of the aqueous phase from the organic phase (8). The separated organic phase is the NVR with low Cr concentration (˜2 ppm).
- Disclosed herein is a process for the production of cyclohexanone and cyclohexanol mixture from cyclohexane together with byproduct recovery, said process comprising: (i) oxidizing cyclohexane to obtain air oxidation tails; (ii) contacting the air oxidation tails with water; (iii) separating the mixture resulting from step (ii) into a first phase and a second phase, said first phase comprising substantially aqueous components and said second phase comprising cyclohexyl hydroperoxide and organic components; (iv) decomposing the cyclohexyl hydroperoxide in the organic phase from step (iii) to cyclohexanone and cyclohexanol; (v) refining of the cyclohexanol and cyclohexanone mixture obtained in step (iv) and (vi) separating chromium from nonvolatile residue.
- Disclosed herein is a method for oxidizing cyclohexane, which subsequently will produce NVR by-product with low Cr content. In the method of the present invention the cyclohexane is contacted with air in the air oxidizer ( 1) at temperatures between about 100° C. to about 175° C. The air oxidizer can be an oxidation tower, stirred or non-stirred tank reactor(s), stirred or non-stirred autoclave(s). The air oxidizer tails are contacted with water. The ratio between the air oxidizer tails and water is about 100:1. After the aqueous phase is separated (2) the cyclohexyl-hydroperoxide is decomposed to K and A (3).
- Decomposition of the CHHP may be accomplished using thermal decomposition, catalytic decomposition, catalytic hydrogenation or other catalytic methods such as the use of gold catalyst, for example. Thermal decomposition is carried out at relatively high temperatures, 120-175° C. and long hold-up times.
- CHHP hydrogenation is carried out with heterogeneous catalysts, at temperatures between about 100 to about 160° C. Hydrogenation catalysts include but not limited to palladium on silica or alumina support.
- CHHP decomposition may also be accomplished without hydrogen with the use of different heterogeneous catalysts such as gold deposited on silica or alumina at temperatures between 100-160° C.
- CHHP decomposition may also be accomplished by metal catalyzed decomposition in caustic aqueous solution. This is done by contacting the CHHP with cobalt, chromium, or a mixture thereof, in caustic solutions, preferably sodium hydroxide. When using either or both of these metals for CHHP decomposition the concentration of Co and/or Cr is between 0.1 and 20 ppm.
- After the CHHP is transformed to K&A the excess cyclohexane is distilled off ( 4) and the resulting KA oil is distilled in KA Refiner at temperatures between from about 90 to about 170° C. (5). Some of the process steps, such as water washing the AOR tails, are beneficial in reducing deactivation of the catalyst but are not essential. Also the cyclohexane distillation and KA oil refining can be performed by different unit operations such as vacuum distillation, steam distillation, etc.
- The NVR remaining in the bottom of the KA Refiner column ( 5) is sent to acid treatment reactor (6). The NVR is contacted in (6) with diluted acid solutions (0.2-10%) at temperatures between about 60 to about 120° C. After the first hydrolysis stage the NVR is contacted with an aqueous electrolyte solution (7) to extract the Cr into the aqueous layer. The extraction step of the Cr in aqueous electrolyte solution can be accomplished at temperatures between about 20 to about 0120° C. The NVR with reduced Cr is separated from the aqueous electrolyte solution in a decanter (8). Depending on actual process parameters, the extraction and hydrolysis steps may need to be repeated in order to reduce the Cr to very low levels. The hydrolysis and extraction steps can be reversed in order.
- The K and A is obtained as a mixture. The product (K and A) is oxidized to produce adipic acid. The oxidizing agent that may be used is nitric acid. The resulting adipic acid may be used in turn to make Nylon products, pharmaceutical additives, food additives, polyurethane, and a host of other applications.
Claims (10)
Priority Applications (8)
| Application Number | Priority Date | Filing Date | Title |
|---|---|---|---|
| US10/242,544 US6703529B1 (en) | 2002-09-12 | 2002-09-12 | Process for oxidation of cyclohexane |
| TW092118221A TW200410924A (en) | 2002-09-12 | 2003-07-03 | Process for oxidation of cyclohexane |
| KR1020057004213A KR20050044918A (en) | 2002-09-12 | 2003-09-09 | Process for oxidation of cyclohexane |
| PCT/US2003/028261 WO2004024657A2 (en) | 2002-09-12 | 2003-09-09 | Process for oxidation of cyclohexane |
| AU2003267072A AU2003267072A1 (en) | 2002-09-12 | 2003-09-09 | Process for oxidation of cyclohexane |
| CNB038215535A CN1319924C (en) | 2002-09-12 | 2003-09-09 | Process for oxidation of cyclohexane |
| EP03749547A EP1539665B1 (en) | 2002-09-12 | 2003-09-09 | Process for oxidation of cyclohexane |
| JP2004536396A JP2005539066A (en) | 2002-09-12 | 2003-09-09 | Cyclohexane oxidation process |
Applications Claiming Priority (1)
| Application Number | Priority Date | Filing Date | Title |
|---|---|---|---|
| US10/242,544 US6703529B1 (en) | 2002-09-12 | 2002-09-12 | Process for oxidation of cyclohexane |
Publications (2)
| Publication Number | Publication Date |
|---|---|
| US6703529B1 US6703529B1 (en) | 2004-03-09 |
| US20040054235A1 true US20040054235A1 (en) | 2004-03-18 |
Family
ID=31887781
Family Applications (1)
| Application Number | Title | Priority Date | Filing Date |
|---|---|---|---|
| US10/242,544 Expired - Lifetime US6703529B1 (en) | 2002-09-12 | 2002-09-12 | Process for oxidation of cyclohexane |
Country Status (8)
| Country | Link |
|---|---|
| US (1) | US6703529B1 (en) |
| EP (1) | EP1539665B1 (en) |
| JP (1) | JP2005539066A (en) |
| KR (1) | KR20050044918A (en) |
| CN (1) | CN1319924C (en) |
| AU (1) | AU2003267072A1 (en) |
| TW (1) | TW200410924A (en) |
| WO (1) | WO2004024657A2 (en) |
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| US6814867B2 (en) * | 2002-09-12 | 2004-11-09 | Inuista North America S.à.r.l. | Process for reducing chromium in nonvolatile residue resulting from air oxidation of cyclohexane |
-
2002
- 2002-09-12 US US10/242,544 patent/US6703529B1/en not_active Expired - Lifetime
-
2003
- 2003-07-03 TW TW092118221A patent/TW200410924A/en unknown
- 2003-09-09 CN CNB038215535A patent/CN1319924C/en not_active Expired - Fee Related
- 2003-09-09 EP EP03749547A patent/EP1539665B1/en not_active Expired - Lifetime
- 2003-09-09 AU AU2003267072A patent/AU2003267072A1/en not_active Abandoned
- 2003-09-09 JP JP2004536396A patent/JP2005539066A/en active Pending
- 2003-09-09 WO PCT/US2003/028261 patent/WO2004024657A2/en not_active Ceased
- 2003-09-09 KR KR1020057004213A patent/KR20050044918A/en not_active Ceased
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Also Published As
| Publication number | Publication date |
|---|---|
| JP2005539066A (en) | 2005-12-22 |
| TW200410924A (en) | 2004-07-01 |
| WO2004024657A3 (en) | 2004-08-05 |
| CN1681759A (en) | 2005-10-12 |
| CN1319924C (en) | 2007-06-06 |
| KR20050044918A (en) | 2005-05-13 |
| WO2004024657A2 (en) | 2004-03-25 |
| EP1539665A4 (en) | 2006-07-26 |
| EP1539665A2 (en) | 2005-06-15 |
| EP1539665B1 (en) | 2011-11-09 |
| US6703529B1 (en) | 2004-03-09 |
| AU2003267072A1 (en) | 2004-04-30 |
| AU2003267072A8 (en) | 2004-04-30 |
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