KR20010052824A - Production of mibk using catalytic distillation technology - Google Patents

Abstract

Process for the production of methyl isobutyl ketone from acetone and hydrogen using a catalytic distillation column reactor. The reaction takes place in the reaction zone where the reaction product is recovered from the reaction zone and unreacted acetone is refluxed. Equilibrium is continuously disturbed greater than the equilibrium conversion of acetone.

Description

Production method of MIBK using catalytic distillation technology {PRODUCTION OF MIBK USING CATALYTIC DISTILLATION TECHNOLOGY}

The present invention relates to the production of methyl isobutyl ketone, which is an important industrial solvent. The present invention relates in particular to a process for producing methyl isobutyl ketone. According to the invention, acetone and hydrogen are introduced into the treatment zone; Catalytic distillation of acetone in the treatment zone in the presence of hydrogen to convert at least a portion of the acetone to methyl isobutyl ketone; A method of producing methyl isobutyl ketone is provided that includes recovering methyl isobutyl ketone from a treatment zone.

Summary of the Invention

Catalytic distillation performs chemical reactions simultaneously with distillation in a single treatment zone or in combination with distillation in a single treatment zone. In the present invention, the following reaction takes place in the treatment zone to produce methyl isobutyl ketone (MIBK):

The dimerization / dehydration reaction (1) is extremely limited in equilibrium under normal operating conditions.

The treatment zone is a dimerization / dehydration reaction that converts acetone to mesityl oxide, i.e. reaction (1), and a hydrogenation reaction that converts mesityl oxide to methyl isobutyl ketone, i.e. At least one reaction zone that occurs, and at least one distillation zone adjacent to the reaction zone where distillation of the reaction products and / or unreacted reactants from the reaction zone occurs.

The catalyst preferably serves two functions. According to this, the catalyst can promote or catalyze the dimerization / dehydration reaction, ie reaction (1) and hydrogenation reaction, ie reaction (2). The dimerization / dehydration function (reaction (1)) of the catalyst, which is inherently acidic, includes ion exchange resins such as divinyl benzene-based cation exchange resins, styrene-based cation exchange resins, and Amberlyst® resins; Zeolite, or alumina, preferably by cation exchange resin. Since the resin has a temperature limit, the temperature conditions in the reaction zone should not exceed about 135 ° C. The hydrogenation function can be provided by metals, preferably Group VIII and Group IB metals of the Periodic Table of Elements, for example nickel, palladium or copper.

The treatment zone will typically be provided by a column. The catalyst may be in the form of particles and arranged in the form of a packing bed located in the reaction zone. The catalyst bed may be located above the point or level where acetone enters the column. Suitable packing distillation media, such as Raschig rings, or distillation apparatus or equipment, are provided in the column, ie, the distillation zone (s), below and / or above the catalyst bed.

The temperature and pressure inside the column are chosen such that the acetone is boiling point at the column pressure. That is, the temperature inside the column is controlled by pressure. The change in acetone boiling point using pressure can be obtained from a known source, such as a model package, for example a model package available under the trademark PRO II from Simulation Sciences, Inc. Preferably the temperature conditions in the column are 50 ° C.-160 ° C., more preferably 100 ° C.-135 ° C. The pressure required to maintain acetone at boiling point under these temperature conditions does not exceed 15 bar.

The introduction of hydrogen into the column is preferably lower than acetone and higher than the reboiler.

Methyl isobutyl ketone, any other by-product and condensed acetone may pass to the base of the reaction zone and these components are reboiled in a reboiling stage located at the base of the column or reaction zone. Methyl isobutyl ketone and any other by-products having a higher boiling point than acetone and are not evaporated significantly by reboiling can be transferred in the form of product fractions or streams.

Acetone evaporated without reaction is recovered at the top of the column, condensed and returned to reflux in the catalyst bed or in a column higher than the catalyst bed.

In one aspect of the invention the process is a continuous process in which acetone is introduced into the column base immediately above the reboiling stage and product fractions or streams are continuously withdrawn from the reboiling stage.

However, in another aspect of the present invention, the process may be a batch process in which acetone is initially introduced into the reboiling stage. The process ends when the desired product is achieved in the reboiling stage, after which the methyl isobutyl ketone-containing product fraction is recovered from the reboiling stage.

1 shows a schematic simple flow diagram of a process according to one aspect of the present invention for producing methyl isobutyl ketone.

2 shows a schematic simple flow diagram of a process according to another embodiment of the present invention for producing methyl isobutyl ketone.

The invention will be described by way of example with reference to the accompanying drawings and the non-limiting examples presented below.

According to FIG. 1, reference numeral 10 generally denotes a process according to one aspect of the invention for producing methyl isobutyl ketone.

Process 10 includes a catalytic distillation column 12 having four zones 14, 16, 18, and 20, where zone 14 is at the bottom and zone 20 is at the top. Zones 14, 16 and 20 are distillation zones and filled with distillation packings such as Rasching rings. Zone 18 is a reaction zone and contains a packed catalyst bed. The catalyst in layer 18 is a combination or mixture of particle catalyst components in the form of particles and having a dimerization / dehydration function such as Amberlyst resin, zeolite or alumina, and a particle catalyst component having a hydrogenation function such as nickel, palladium or copper.

The acetone supply line 24 passes through the zone 16 while the hydrogen supply line 22 communicates with the zone 14.

The reboiler 26 is located at the lower end 12 of the column and is equipped with suitable heating means 28, such as a steam heating coil or electric heating element, to which the product recovery line 30 is connected from the reboiler 26. .

The vapor recovery line 32 is connected to the condenser 34 from the top of the column 12 and a return or reflux line in which cooling or condensing means 36, such as cooling water, is connected back to the zone 20 of the column 12. 38 is supplied. Hydrogen recovery line 40 is connected from reflux line 38 to recover excess hydrogen through a back pressure regulator (not shown) mounted to line 40.

If acetone feed line 24 and hydrogen supply line 22 are located below the catalyst bed, the catalyst bed may be located in another zone of column 12 instead of located in zone 18.

In use liquid acetone is fed to the zone 16 of the column 12 via an acetone supply line 24. At the same time, hydrogen gas is introduced into the zone 16 of the column 14 via the hydrogen supply line 22.

The temperature inside column 12 is controlled by pressure. The pressure and temperature conditions are selected so that acetone changes the boiling point of acetone and under the selected pressure conditions the pressure can be obtained from a model package available under the trademark PRO II of Simulation Sciences Inc. According to this, the temperature in the distillation column 12 may be maintained in the region of 100 ° C.-135 ° C. at a pressure controlled to acetone to boiling point. Inherently, the reboiler 26 evaporates the acetone resulting and keeps it in the vapor state.

The gaseous hydrogen and evaporated acetone move over the column 12 and react inside the catalyst bed of the reaction zone 18. Mesityl oxide (MSO) is initially formed according to reaction (1) described above. Mesityl oxide is subsequently hydrogenated to methyl isobutyl ketone (MIBK) according to reaction (2) described above.

The methyl isobutyl ketone formed and any other by-products have a higher boiling point than the acetone feed and are moved along the product recovery line 30 upon entering the reboiler 26.

Unreacted acetone is refluxed at the top of column 12 and recovered along flow line 32, condensed in condenser 34 and then returned to the top of column along flow line 38. No light boiling component is formed in reactions (1), (2) and (3), so there is no overhead product recovered in column 12. That is, column 12 is operated under full reflux. Unreacted hydrogen is recovered along flow line 40.

The methyl isobutyl ketone product is formed in one step using a single catalytic distillation column 12.

If necessary, ie, depending on the selectivity of the catalyst used, the by-products formed are separated from methyl isobutyl ketone in another downstream distillation column (not shown) and enter the flow line 30.

According to FIG. 2, reference numeral 50 generally denotes a process according to another embodiment of the invention for producing methyl isobutyl ketone.

Parts of the process 50 that are the same as or similar to the process 10 described in FIG. 1 have the same reference numerals.

Process 50 includes column 52. Column 52 is similar to column 12 except that it has only three zones 54, 56, 58, and zone 54 is at the bottom and zone 58 is at the top. Distillation media, such as Raschig rings, are located in the distillation zones 54 and 58, but the catalyst bed is provided in the reaction zone 56. The hydrogen supply line 22 is connected to the zone 54 at the bottom of this zone.

Process 50 is a batch process and there is no acetone feed line to column 52. However, the batch of acetone is initially introduced into the reboiler 26.

The reboiler 26 is electrically heated since the heating means 28 is in the form of an electric heating element.

In use, acetone and hydrogen gas evaporated in the reboiler 26 travel upward through the catalyst bed of the zone 56. Unreacted acetone exits through flow line 32, condenses in condenser 34 and then returns to the top of the column through flow line 38. Unreacted hydrogen is recovered along flow line 40.

The high boiling methyl isobutyl ketone product, and any other by-products formed, fall into the reboiler 26. The contents of the reboiler 26 are analyzed periodically. Since the pressure conditions inside the column are tailored to favor boiling of acetone, higher boiling products are unable to boil in the reboiler and therefore move to column 52. Only acetone present in the reboiler 26 boils and evaporates and moves to column 52. Accordingly, more methyl isobutyl ketone and other by-products accumulate in the reboiler 26 until the effective acetone for the reaction is gradually lost. If all effective acetone is used, there will be no components passing through the flow line 32 so the condenser efficiency will drop to zero at which point the reaction is terminated and the methyl isobutyl ketone product is recovered along the flow line 30.

In order to show that the acetone dimerization / dehydration reaction, ie reaction (1) is extremely equilibrium under certain reaction conditions and thus the catalytic distillation technique is very advantageous, Example 1 was performed:

Acetone dimerization / dehydration reaction (reaction (1)) was performed in a batch autoclave over 48 hours to obtain conversion data close to equilibrium values. 100 ml of acetone and 15 ml of particles 0.05% Pd / Amberlyst Rhom & Haas 15 catalyst were charged to an autoclave or reactor. The reactor was purged twice with nitrogen and then pressurized to 5 bar with nitrogen. The reactor was subsequently heated to 110 ° C. at a stirrer speed of 200 rpm for 48 hours. After cooling, the contents of the reactor were analyzed by gas chromatography (GC) and the results obtained in this experiment are shown in Table 1.

As can be seen from Table 1, the conversion of acetone is 10% or less, indicating that the acetone dimerization reaction is extremely limited in equilibrium under defined reaction conditions and may be advantageous by catalytic distillation techniques.

Table 1

Acetone Conversion% Product Name Selectivity%

MSO + isomer 82.31

7.3 remaining 17.69

Unexpectedly, it has been found that catalytic distillation has the advantage of increasing the conversion of the equilibrium limited acetone dimerization reaction of Example 1. To this end, in Example 2, a batch catalytic distillation column was used, substantially free of hydrogen supply, according to FIG. 3.

Example 2

100 ml of particles 0.05% Pd / Amberlyst 15 catalyst were packed in the reaction zone 56 of the batch distillation column 52 and the remaining zones or zones 54 and 58 were filled with 6 mm Raschig ring distillation packing. One liter of acetone was charged to the reboiler of the column. The column was pressurized to 5 bar with nitrogen. Heating of the reboiler was started and samples from the reboiler were taken periodically and GC analysis was performed.

The data obtained in the run is shown in Table 2 below. Higher conversions are obtained when using catalytic distillation than when using a conventional batch reactor under reaction conditions similar to Example 1. The results of this example clearly demonstrate that catalytic distillation techniques have the advantage of increasing conversion of equilibrium limited acetone dimerization reactions.

In Example 3, while repeating Example 1, autoclave was pressurized using hydrogen instead of nitrogen.

Example 3

The reaction conditions are the same as those described in Example 1. However, the autoclave was pressurized to 5 bar for 48 hours using hydrogen instead of nitrogen.

The results obtained in this run are given in Table 3. Acetone conversion is higher when using hydrogen instead of nitrogen because mesityl oxide is hydrogenated to methyl isobutyl ketone to help the equilibrium shift towards the product or methyl isobutyl ketone. However, acetone conversion is lower when catalytic distillation techniques are used in the absence of hydrogen (Table 2). In addition, large amounts of other products are still formed in the presence of hydrogen. These other products are by-products of further reaction with MSOs such as poron, isophorone, mesitylene and the like.

TABLE 3

Acetone Conversion% Product Name Selectivity%

MSO + Isomer 19.25

25.56 remaining 18.93

MIBK 61.19

In Example 4, while repeating Example 2, the column was pressurized using a hydrogen feed, ie hydrogen.

Example 4

The reaction was carried out in the same batch catalytic distillation column as used in Example 2, but the column was pressurized with hydrogen. Hydrogen was passed through the catalyst or reaction zone at a flow rate of 7 normal liters per hour. The results are given in Table 4. These results show that catalytic distillation enhances the conversion of acetone. However, not all of the mesityl oxides formed are hydrogenated to methyl isobutyl ketone due to the low hydrogen flow rate used under the low pressure conditions (5 bar) used in this run.

In Example 5, while repeating Example 4, a higher hydrogen flow rate was used.

Example 5

Acetone dimerization was performed as in Example 4. The hydrogen flow rate was increased to 12 normal liters per hour. The results are shown in Table 5. Increasing the hydrogen flow rate results in more methyl isobutyl ketone from mesityl oxide hydrogenation; Not all of the mesityl oxides formed are converted to methyl isobutyl ketone. This indicates that higher hydrogen flow rates are desirable under the low pressure conditions of 5 bar used in this run, or it is necessary to increase the pressure above 5 bar while maintaining a hydrogen flow rate of 12 normal liters per hour.

In Example 6 the pressure was maintained at 5 bar and the hydrogen flow rate was further increased.

Example 6

Acetone dimerization was carried out as in Example 5. The hydrogen flow rate was increased to 55 normal liters per hour. The results are shown in Table 6. As the hydrogen flow rate increases, more methyl isobutyl ketone is formed from mesityl oxide hydrogenation. It can be seen from Tables 5 and 6 that less byproducts are formed when the hydrogen flow rate increases from 12 to 55 normal liters per hour.

Claims (22)

Acetone and hydrogen are introduced into the treatment zone; Catalytic distillation of acetone in the presence of hydrogen in the treatment zone to convert at least a portion of the acetone to methyl isobutyl ketone; A method for producing methyl isobutyl ketone, comprising recovering methyl isobutyl ketone from a treatment zone. The process zone according to claim 1, wherein the treatment zone comprises: (i) a dimerization / dehydration reaction for converting acetone to mesityl oxide, and at least one reaction zone in which hydrogenation reaction for converting mesityl oxide to methyl isobutyl ketone occurs in the presence of a catalyst. And (ii) at least one distillation zone adjacent to the reaction zone from which reaction products and / or unreacted reactants from the reaction zone are distilled. 3. The process of claim 2, wherein the catalyst is a bifunctional (2) which promotes or catalyzes the dimerization / dehydration reaction and the hydrogenation reaction. 4. The process of claim 3 wherein the catalyst comprises (i) an ion exchange resin, zeolite or alumina that promotes or catalyzes the dimerization / dehydration reaction, and (ii) nickel, palladium or copper that promotes or catalyzes the hydrogenation reaction. 5. The process according to claim 2, wherein the catalyst is in the form of particles and is provided in the form of a packed bed located at a reaction zone higher than the point or level at which acetone is introduced into the column, and the packed distillation medium is provided in the distillation zone. Wherein the column is provided in a treatment zone, characterized in that in (s) it is provided in a column lying below and / or above the catalyst bed. 6. The method of claim 5 wherein the temperature and pressure inside the column cause acetone to boil at column pressure. 7. Process according to claim 5 or 6, wherein the hydrogen introduction into the column is below the level of acetone but below the catalyst bed. 8. The process of claim 7, wherein methyl isobutyl ketone, any other by-products formed and condensed acetone are passed through the base of the reaction zone; Reboiling these components at the reboiling stage; Transferring methyl isobutyl ketone and any other byproducts in the form of a product fraction or stream having a boiling point higher than acetone and not significantly evaporated by reboiling. The method of claim 8, wherein unreacted evaporated acetone is recovered from the top of the column; Condensation of the recovered evaporated acetone; Returning the condensed acetone in a reflux form to the catalyst bed or to a column above the catalyst bed. 10. The process according to claim 8 or 9, wherein the process is a continuous process in which acetone is introduced into the base of the column immediately above the reboiling stage and the product fraction or stream is withdrawn continuously from the reboiling stage. 10. The methyl isobutyl ketone-containing product fraction is recovered from the reboiling stage according to claim 8 or 9, after the process initially introduces acetone into the reboiling stage and ends when a particular product is obtained in the reboiling stage. How to be a batch process. Novel process for producing methyl isobutyl ketone specifically described and described herein. (a) acetone and hydrogen are charged in a catalytic distillation column containing a bifunctional catalyst in the reaction zone; (b) simultaneously in the reaction zone; (i) reacting acetone with hydrogen to produce a reaction mixture containing a reaction product containing unreacted acetone, unreacted hydrogen and methyl isobutyl ketone, (ii) separating the reaction product containing methyl isobutyl ketone from unreacted acetone and unreacted hydrogen; (c) recovering the reaction product from the catalytic distillation column at a point below the reaction zone; (d) recovering unreacted acetone and unreacted hydrogen from the catalytic distillation column at a point higher than the reaction zone. The method of claim 13, wherein the bifunctional catalyst comprises an acidic ion exchange resin in combination with a Group VII or Group IB hydrogenated metal. 15. The process of claim 14, wherein the catalyst comprises 0.05 wt% Pd on the cation exchange resin. The method of claim 13, wherein the bifunctional catalyst comprises a zeolite in combination with a Group VIII or Group IB hydrogenated metal. The process of claim 13, wherein unreacted acetone and unreacted hydrogen are recovered from the catalytic distillation column in overhead form. 18. The process of claim 17, wherein the overhead is cooled to condense unreacted acetone and substantially all of the acetone is returned to the catalytic distillation column in overhead form. The process of claim 13, wherein the reaction product is recovered from the catalytic distillation column in the form of a sediment. The method of claim 13, wherein the reaction product comprises methyl isobutyl ketone and mesityl oxide. The process of claim 20, wherein the reaction product is further processed to separate methyl isobutyl ketone from mesityl oxide. (a) acetone and hydrogen are charged in a catalytic distillation column containing a catalyst comprising 0.05 wt% Pd on an ion exchange resin in the reaction zone; (b) simultaneously in the reaction zone; (i) reacting acetone with hydrogen to produce a reaction mixture containing unreacted acetone, unreacted hydrogen and a reaction product containing methyl isobutyl ketone and mesityl oxide; (ii) separating the reaction product containing methyl isobutyl ketone and mesityl oxide from unreacted acetone and unreacted hydrogen; (c) recovering the reaction product from the catalytic distillation column in the form of sediment; (d) recovering unreacted acetone and unreacted hydrogen from the catalytic distillation column in overhead form; (e) cooling the overhead to condense unreacted acetone; (f) returning substantially all acetone to the catalytic distillation column in reflux form; (g) separating methyl isobutyl ketone from the remaining reaction product.