US20100048943A1 - Process for production of isophthalic acid - Google Patents

Process for production of isophthalic acid Download PDF

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US20100048943A1
US20100048943A1 US12/520,625 US52062507A US2010048943A1 US 20100048943 A1 US20100048943 A1 US 20100048943A1 US 52062507 A US52062507 A US 52062507A US 2010048943 A1 US2010048943 A1 US 2010048943A1
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acetic acid
mother liquor
mass
liquid
hydrous acetic
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Fumiya Zaima
Nobuo Namiki
Hideaki Fujita
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Mitsubishi Gas Chemical Co Inc
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Mitsubishi Gas Chemical Co Inc
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Assigned to MITSUBISHI GAS CHEMICAL COMPANY, INC. reassignment MITSUBISHI GAS CHEMICAL COMPANY, INC. ASSIGNMENT OF ASSIGNORS INTEREST (SEE DOCUMENT FOR DETAILS). Assignors: FUJITA, HIDEAKI, NAMIKI, NOBUO, ZAIMA, FUMIYA
Publication of US20100048943A1 publication Critical patent/US20100048943A1/en
Assigned to MITSUBISHI GAS CHEMICAL COMPANY, INC. reassignment MITSUBISHI GAS CHEMICAL COMPANY, INC. ASSIGNMENT OF ASSIGNORS INTEREST (SEE DOCUMENT FOR DETAILS). Assignors: FUJITA, HIDEAKI, INARI, MASATO, NAMIKI, NOBUO, ZAIMA, FUMIYA
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    • C—CHEMISTRY; METALLURGY
    • C07—ORGANIC CHEMISTRY
    • C07C—ACYCLIC OR CARBOCYCLIC COMPOUNDS
    • C07C63/00—Compounds having carboxyl groups bound to a carbon atoms of six-membered aromatic rings
    • C07C63/14—Monocyclic dicarboxylic acids
    • C07C63/15—Monocyclic dicarboxylic acids all carboxyl groups bound to carbon atoms of the six-membered aromatic ring
    • C07C63/26—1,4 - Benzenedicarboxylic acid
    • C—CHEMISTRY; METALLURGY
    • C07—ORGANIC CHEMISTRY
    • C07C—ACYCLIC OR CARBOCYCLIC COMPOUNDS
    • C07C51/00—Preparation of carboxylic acids or their salts, halides or anhydrides
    • C07C51/42—Separation; Purification; Stabilisation; Use of additives
    • C07C51/47—Separation; Purification; Stabilisation; Use of additives by solid-liquid treatment; by chemisorption
    • C—CHEMISTRY; METALLURGY
    • C07—ORGANIC CHEMISTRY
    • C07C—ACYCLIC OR CARBOCYCLIC COMPOUNDS
    • C07C51/00—Preparation of carboxylic acids or their salts, halides or anhydrides
    • C07C51/16—Preparation of carboxylic acids or their salts, halides or anhydrides by oxidation
    • C07C51/21—Preparation of carboxylic acids or their salts, halides or anhydrides by oxidation with molecular oxygen
    • C07C51/255—Preparation of carboxylic acids or their salts, halides or anhydrides by oxidation with molecular oxygen of compounds containing six-membered aromatic rings without ring-splitting
    • C07C51/265—Preparation of carboxylic acids or their salts, halides or anhydrides by oxidation with molecular oxygen of compounds containing six-membered aromatic rings without ring-splitting having alkyl side chains which are oxidised to carboxyl groups

Definitions

  • the present invention relates to a method for producing isophthalic acid.
  • Isophthalic acid is effectively employed as an intermediate of polymers such as unsaturated polyester resin, alkyd resin, modified polyester fiber, heat-resistant polyamide, and isophthalic-acid-modified co-polyester resin.
  • isophthalic acid is produced through liquid-phase oxidation reaction of a m-phenylene compound (e.g., m-xylene) in acetic acid serving as a solvent in the presence of a catalyst (e.g., cobalt or manganese), or in the presence of a catalyst together with a promoter (e.g., a bromine compound or acetaldehyde).
  • a catalyst e.g., cobalt or manganese
  • a promoter e.g., a bromine compound or acetaldehyde
  • a mother liquor recovered through the solid-liquid separation contains catalyst-derived useful catalyst components such as heavy metal ions and bromide ions, and an industrial process requires recycling of these catalyst components for reduction of production cost.
  • the mother liquor is returned, as it is, to and reused in the reaction system.
  • the mother liquor contains, for example, various organic impurities by-produced through liquid-phase oxidation reaction, and inorganic impurities derived from corrosion of an employed apparatus, when the mother liquor is reused as it is in the reaction system, the concentration of these impurities is gradually increased in the reaction system, and an increase in impurity concentration beyond a predetermined level adversely affects liquid-phase oxidation reaction.
  • the mother liquor is generally returned to the reaction system in a proportion of 60 to 90%, and the remaining portion (10 to 40%) of the mother liquor (i.e., a portion of the mother liquor which is not reused in the reaction system) is fed to a step of recovering acetic acid serving as a solvent.
  • various methods have been proposed for recovering catalyst components from the mother liquor fed to such an acetic acid recovery step, and reusing the catalyst components.
  • such known methods include a method in which water and an alkali metal carbonate salt are added to a residue obtained through recovery of a solvent from a mother liquor, to thereby cause a catalyst component in the form of carbonate salt to precipitate, and the catalyst component is dissolved in a predetermined amount of acetic acid serving as a solvent, and reused for reaction (see Patent Document 1); and a method in which oxalic acid and an alkali metal hydroxide are added to a mother liquor, to thereby cause a catalyst component in the form of oxalate salt to precipitate, and the catalyst component is dissolved in acetic acid serving as a solvent, followed by oxidation for recovery of the catalyst component (see Patent Document 2).
  • Patent Documents 3 to 11 There have also been known methods for recovering a catalyst component from a mother liquor by use of an anion exchange resin (see Patent Documents 3 to 11), including a method in which a bromide-ion-type anion exchange resin is exposed to a mother liquor for adsorption of cobalt ions and manganese ions on the resin, hydrous acetic acid having a water content of 2 mass % and water are caused to pass through the resin, to thereby recover cobalt ions and manganese ions through elution, a lower-aliphatic-monocarboxylate-ion-type weakly basic anion exchange resin is exposed to an eluate obtained through the aforementioned adsorption for adsorption of bromide ions and nickel ions on the resin, and hydrous acetic acid having a water content of 2 mass % and water are caused to pass through the resin, to thereby recover bromide ions and nickel ions through elution (see Patent Document 3); a method in which the
  • Patent Document 1 Japanese Patent Application Laid-Open (kokai) No. S48-66090
  • Patent Document 2 Japanese Patent Application Laid-Open (kokai) No. H02-203939
  • Patent Document 3 Japanese Patent Application Laid-Open (kokai) No. S53-104590
  • Patent Document 4 Japanese Patent Application Laid-Open (kokai) No. S53-133574
  • Patent Document 5 Japanese Patent Application Laid-Open (kokai) No. S53-102290
  • Patent Document 6 Japanese Patent Application Laid-Open (kokai) No. H10-15390
  • Patent Document 7 Japanese Patent Application Laid-Open (kokai) No.
  • Patent Document 8 Japanese Patent Application Laid-Open (kokai) No. 2002-12573
  • Patent Document 9 Specification of U.S. Pat. No. 4,162,991
  • Patent Document 10 Specification of U.S. Pat. No. 4,238,294
  • Patent Document 11 Japanese Kohyo Patent Publication No. 2003-507160
  • Patent Document 1 or 2 requires, for example, an alkali metal carbonate salt or oxalic acid in an amount equivalent to or greater than that of a catalytic metal, and thus is economically disadvantageous.
  • the method requires an intricate process and a great deal of labor for recovery of a catalyst component in the form of carbonate salt or oxalate salt, which is not preferred.
  • the anion exchange resins described in Patent Documents 3 to 6 and 8 to 11 exhibit low heat resistance (allowable temperature limit: 80 to 100° C.), and thus may undergo chemical degradation (reduction in exchange capacity) or physical degradation (e.g., breakage of the resin) depending on the temperature of a mother liquor which has been caused to pass through the resins, which is not preferred.
  • Patent Document 7 employs an anion-exchange-type “chelate resin,” and is advantageous in that, unlike the case of the pyridine-ring-containing anion exchange resin described in Patent Document 5, cobalt ions, manganese ions, and bromide ions adsorbed on the chelate resin can be eluted with hydrous acetic acid having a water content of 1 to 15 mass %.
  • a mother liquor recovered through the method of the present invention i.e., a mother liquor recovered through solid-liquid separation of a slurry produced by liquid-phase oxidation reaction of a m-phenylene compound
  • a carboxylic acid mixture which has been by-produced hereinafter may be referred to as a “by-produced carboxylic acid mixture”
  • the by-produced carboxylic acid mixture is adsorbed on the chelate resin, and, upon elution of cobalt ions, manganese ions, and bromide ions, the by-produced carboxylic acid mixture is eluted and recovered together with these ions.
  • an object of the present invention for solving the aforementioned problems is to provide a method for producing, in an industrially advantageous manner, isophthalic acid by use of a specific chelate resin while suppressing an increase in concentration of a by-produced carboxylic acid mixture in a reaction system and a mother liquor.
  • the present invention provides:
  • a m-phenylene compound to liquid-phase oxidation reaction by use of a molecular-oxygen-containing gas in the presence of a catalyst at least containing a heavy metal compound and a bromine compound, and hydrous acetic acid having a water content of 1 to 15 mass %, to thereby yield a slurry;
  • an adsorption step including regulating the ratio “amount by mole of bromide ions in the mother liquor/total amount by mole of heavy metal ions in the mother liquor” to 0.3 to 3, and then exposing the mother liquor to a pyridine-ring-containing chelate resin which has been heated to 35 to 140° C., so that the resin adsorbs catalyst-derived heavy metal ions and bromide ions, and also adsorbs a carboxylic acid mixture which has been by-produced through the liquid-phase oxidation reaction (hereinafter the carboxylic acid mixture will be referred to as a “by-produced carboxylic acid mixture”),
  • isophthalic acid In the method for producing isophthalic acid, a by-produced carboxylic acid mixture can be effectively separated from catalyst-derived heavy metal ions and bromide ions, and the thus-recovered heavy metal ions and bromide ions can be reused, as it is, as a catalyst in liquid-phase oxidation reaction. Therefore, isophthalic acid can be produced stably in a more economically advantageous manner while high reaction yield is maintained over a long period of time.
  • FIG. 1 shows an exemplary process for producing isophthalic acid.
  • a m-phenylene compound is subjected to liquid-phase oxidation reaction by use of a molecular-oxygen-containing gas in the presence of a catalyst at least containing a heavy metal compound and a bromine compound, and hydrous acetic acid having a water content of 1 to 15 mass % (preferably 1 to 14 mass %, more preferably 1 to 9 mass %), to thereby yield a slurry (hereinafter the thus-obtained slurry may be referred to as an “oxidation reaction slurry”).
  • the term “m-phenylene compound” refers to a phenylene compound having substituents at positions 1 and 3 of the benzene ring. Examples of such a substituent include alkyl groups such as methyl, ethyl, propyl, and butyl.
  • a particularly preferred m-phenylene compound is m-xylene.
  • At least one of a cobalt compound and a manganese compound is essentially employed as a heavy metal compound (i.e., a catalyst component), and optionally, for example, a nickel compound, a cerium compound, or a zirconium compound may be employed together with such an essential heavy metal compound.
  • a heavy metal compound i.e., a catalyst component
  • a nickel compound, a cerium compound, or a zirconium compound may be employed together with such an essential heavy metal compound.
  • the cobalt compound, manganese compound, nickel compound, cerium compound, and zirconium compound include organic acid salts, hydroxides, halides, and carbonates of the respective metals. Particularly, acetic acid salts and bromides of the respective metals are preferably employed.
  • such a heavy metal compound include cobalt acetate, cobalt hydroxide, cobalt fluoride, cobalt chloride, cobalt bromide, cobalt iodide, cobalt carbonate, manganese acetate, manganese hydroxide, manganese fluoride, manganese chloride, manganese bromide, manganese iodide, manganese carbonate, nickel acetate, nickel hydroxide, nickel fluoride, nickel chloride, nickel bromide, nickel iodide, nickel carbonate, cerium acetate, cerium hydroxide, cerium fluoride, cerium chloride, cerium bromide, cerium iodide, cerium carbonate, zirconium acetate, zirconium hydroxide, zirconium fluoride, zirconium chloride, zirconium bromide, zirconium iodide, and zirconium carbonate.
  • bromine compound employed as a catalyst component dissolves in hydrous acetic acid and generates bromide ions in the reaction system.
  • the bromine compound include inorganic bromine compounds such as hydrogen bromide, sodium bromide, and cobalt bromide; and organic bromine compounds such as bromoacetic acid and tetrabromoethane.
  • hydrogen bromide, cobalt bromide, and manganese bromide are preferably employed.
  • hydrobromic acid prepared by dissolving hydrogen bromide in an aqueous solution is employed.
  • the liquid-phase oxidation reaction is preferably performed at 160 to 230° C., more preferably 180 to 210° C.
  • the reaction temperature falls within the above range, the amount of a reaction intermediate remaining in the oxidation reaction slurry can be reduced, and excessive loss of hydrous acetic acid having a water content of 1 to 15 mass % (i.e., a solvent) by combustion is prevented.
  • No particular limitation is imposed on the reaction pressure, so long as the reaction system can be maintained in a liquid phase at the aforementioned reaction temperature.
  • the reaction pressure is preferably 0.78 to 3.04 MPa, more preferably 0.98 to 1.86 MPa.
  • Examples of a molecular-oxygen-containing gas include air, oxygen gas diluted with an inert gas, and oxygen-enriched air. Generally, air is preferred, from the viewpoints of facility and cost.
  • the oxidation reaction slurry obtained through the aforementioned liquid-phase oxidation reaction is fed to the subsequent reactor connected in series, so as to thoroughly complete oxidation reaction by use of a molecular-oxygen-containing gas.
  • the thus-obtained oxidation reaction slurry is subjected to pressure reduction and cooling (35 to 140° C.) through flash evaporation in one or more stages in a crystallization step employing one or more crystallization tanks, to thereby thoroughly crystallize crude isophthalic acid, and then the slurry is fed to the below-described solid-liquid separator.
  • the oxidation reaction slurry obtained through the aforementioned liquid-phase oxidation reaction is separated into crude isophthalic acid crystals and a mother liquor by means of a solid-liquid separator.
  • This solid-liquid separation is generally performed at atmospheric pressure. No particular limitation is imposed on the separation temperature, but this separation is generally performed at a temperature lower than the boiling point of hydrous acetic acid at atmospheric pressure (e.g., 35 to 110° C.).
  • the solid-liquid separator include a centrifugal separator, a centrifugal filter, and a vacuum filter. This solid-liquid separation is preferably performed so that the crystal content of the mother liquor is 1 mass % or less, more preferably 0.1 mass % or less.
  • the thus-obtained crude isophthalic acid crystals may be appropriately subjected to a known purification process, such as catalytic hydrogenation (see, for example, Japanese Patent Publication (kokoku) No. S41-16860), oxidation treatment, or recrystallization, to thereby yield isophthalic acid crystals of high purity.
  • a known purification process such as catalytic hydrogenation (see, for example, Japanese Patent Publication (kokoku) No. S41-16860), oxidation treatment, or recrystallization, to thereby yield isophthalic acid crystals of high purity.
  • the mother liquor recovered through separation of crude isophthalic acid crystals from the oxidation reaction slurry by the aforementioned procedure contains catalyst-derived heavy metal ions and bromide ions, and a by-produced carboxylic acid mixture. These heavy metal ions are ions of the heavy metals constituting the aforementioned heavy metal compounds.
  • the by-produced carboxylic acid mixture includes aromatic polycarboxylic acids each having carboxyl groups which are ortho to each other. Examples of such an aromatic polycarboxylic acid include trimellitic acid compounds (e.g., trimellitic acid, hemimellitic acid, and 5-methyltrimellitic acid); pyromellitic acid; and phthalic acid compounds (e.g., phthalic acid, 3-methylphthalic acid, and 4-methylphthalic acid).
  • the mother liquor contains, in addition to the aforementioned ions and by-produced carboxylic acid mixture, various organic compounds (e.g., isophthalic acid, acetic acid, unreacted raw materials, reaction intermediates, and reaction by-products), and a considerable amount of water (i.e., a reaction product).
  • various organic compounds e.g., isophthalic acid, acetic acid, unreacted raw materials, reaction intermediates, and reaction by-products
  • water i.e., a reaction product
  • the ratio “amount by mole of bromide ions in the mother liquor/total amount by mole of heavy metal ions in the mother liquor” (hereinafter the ratio may be referred to as “the bromide ratio (of the mother liquor)”) is regulated, and then a pyridine-ring-containing chelate resin is exposed to the mother liquor, to thereby selectively adsorb catalyst-derived heavy metal ions, bromide ions, and a by-produced carboxylic acid mixture on the pyridine-ring-containing chelate resin, whereby a liquid (hereinafter the thus-obtained liquid may be referred to as a “residual mother liquor”) is recovered [adsorption step].
  • the pyridine-ring-containing chelate resin employed in the present invention is an anion-exchange-type chelate resin having a pyridine ring and obtained through polymerization of 4-vinylpyridine and divinylbenzene serving as main raw materials.
  • a chelate resin is a water-insoluble polymer base having a ligand which can coordinate with metal ions to form a complex, and exhibits a function of selectively adsorbing/separating specific metal ions.
  • a ‘pyridine-ring-containing’ chelate resin is advantageous in that it effectively adsorbs heavy metal ions.
  • Such a pyridine-ring-containing chelate resin may be a commercially available one.
  • Examples of commercially available pyridine-ring-containing chelate resins include “REILLEX (registered trademark) 425 Polymer” (trade name, product of Reilly) and “Sumichelate (registered trademark) CR-2” (trade name, product of Sumitomo Chemical Co., Ltd.).
  • No particular limitation is imposed on the method for exposing a pyridine-ring-containing chelate resin to the mother liquor, and, for example, the chelate resin is impregnated with the mother liquor, or the mother liquor is caused to pass through the chelate resin.
  • the mother liquor is caused to pass through a pyridine-ring-containing chelate resin.
  • the chelate resin must be heated to 35 to 140° C. before being exposed to the mother liquor.
  • the chelate resin is preferably heated to 45 to 130° C., more preferably 70 to 120° C., much more preferably 85 to 110° C.
  • the residual mother liquor obtained by exposing the mother liquor to a pyridine-ring-containing chelate resin contains hydrous acetic acid having a water content of 1 to 15 mass %. Therefore, preferably, the hydrous acetic acid is recovered from the residual liquid through, for example, distillation, and at least a portion of the thus-recovered hydrous acetic acid is reused in liquid-phase oxidation reaction, or employed as a displacement liquid for the below-described regeneration of the pyridine-ring-containing chelate resin.
  • the mother liquor obtained through liquid-phase oxidation reaction and solid-liquid separation generally has a water content of 7 to 16 mass %. Therefore, when the mother liquor is applied to a pyridine-ring-containing chelate resin column, in many cases, the water content of the mother liquor is not particularly required to be regulated. However, when the water content of the mother liquor is increased by, for example, mixing the mother liquor with a liquid obtained through the aforementioned washing of crude isophthalic acid crystals recovered by solid-liquid separation, the water content is preferably regulated to 16 mass % or less (more preferably 1 to 15 mass %, much more preferably 5 to 14 mass %) through, for example, distillation.
  • the pyridine-ring-containing chelate resin which has not undergone any preliminary treatment may be exposed to the mother liquor.
  • the mother liquor is brought into contact with a bromide-type chelate resin prepared by exposing a pyridine-ring-containing chelate resin to, for example, an acetic acid solution containing bromide ions in advance.
  • the chelate resin may be prepared by exposing a pyridine-ring-containing chelate resin to an aqueous solution of any of the aforementioned bromine compounds (e.g., sodium bromide and hydrogen bromide) or a liquid mixture of the aqueous solution and acetic acid, followed by removal of excess bromide through washing with glacial acetic acid or hydrous acetic acid having a water content of 15 mass % or less. This washing is preferably performed with hydrous acetic acid having a water content lower than that of the mother liquor.
  • the a pyridine-ring-containing chelate resin may be prepared by exposing a pyridine-ring-containing chelate resin to an aqueous solution of any of the aforementioned bromine compounds (e.g., sodium bromide and hydrogen bromide) or a liquid mixture of the aqueous solution and acetic acid, followed by removal of excess bromide through washing with glacial acetic acid or hydrous acetic acid having a water content of
  • the bromide ratio of the mother liquor is 0.3 to 3, preferably 0.6 to 2.8, more preferably 0.8 to 2.5, much more preferably 1.4 to 2.5, particularly preferably 2 to 2.5.
  • the bromide ratio is high, percent adsorption of the aforementioned heavy metal ions is increased, and percent adsorption of a by-produced carboxylic acid mixture tends to be reduced.
  • the bromide ratio is increased particularly in the adsorption step, in the below-described elution step (A), a by-produced carboxylic acid mixture can be effectively separated from catalyst components (i.e., heavy metal ions and bromide ions).
  • the bromide ratio is regulated by, for example, adding, to the mother liquor, an aqueous solution of any of the aforementioned bromine compounds (e.g., hydrobromic acid) serving as a bromide source.
  • the pyridine-ring-containing chelate resin which has undergone the aforementioned adsorption step is subjected to an elution step (A); i.e., a step of exposing the resin to hydrous acetic acid having a water content of 1 to 15 mass % (preferably 1 to 14 mass %, more preferably 1 to 9 mass %), thereby selectively eluting a by-produced carboxylic acid mixture, and then is subjected to an elution step (B); i.e., a step of exposing the resin to water or hydrous acetic acid having a water content of 20 mass % or more, thereby recovering catalyst-derived heavy metal ions and bromide ions.
  • A i.e., a step of exposing the resin to hydrous acetic acid having a water content of 1 to 15 mass % (preferably 1 to 14 mass %, more preferably 1 to 9 mass %), thereby selectively eluting a by-produced carboxylic acid mixture, and
  • the pyridine-ring-containing chelate resin which has undergone the aforementioned adsorption step contains, in addition to catalyst-derived heavy metal ions and bromide ions, a by-produced carboxylic acid mixture.
  • the pyridine-ring-containing chelate resin is subjected to the elution step (B) without being subjected to the elution step (A), so as to recover the heavy metal ions and bromide ions (i.e., catalyst components), the by-produced carboxylic acid mixture is contained in the catalyst components.
  • the concentration of the by-produced carboxylic acid mixture is gradually increased in the reaction system and the mother liquor, which causes deactivation of the catalyst.
  • the elution step (A) is required; i.e., the by-produced carboxylic acid mixture is selectively eluted, with heavy metal ions and bromide ions being adsorbed on the pyridine-ring-containing chelate resin.
  • the hydrous acetic acid having a water content of 1 to 15 mass % and employed in the elution step (A) preferably contains bromide ions in an amount of 1 to 1,000 mass ppm, more preferably 10 to 1,000 mass ppm, for rapidly eluting the by-produced carboxylic acid mixture adsorbed on the pyridine-ring-containing chelate resin.
  • acetic acid water content: 4 to 12 mass %, bromide ion content: 1 to 50 mass ppm
  • acetic acid water content: 4 to 12 mass %, bromide ion content: 1 to 50 mass ppm
  • a displacement liquid employed in the below-described displacement step.
  • the ratio Q/V is preferably 0.5 to 10, more preferably 1 to 6, much more preferably 3 to 4.5.
  • the ratio Q/V falls within the above range, the by-produced carboxylic acid mixture can be effectively and selectively eluted from the pyridine-ring-containing chelate resin.
  • hydrous acetic acid having a water content of 1 to 15 mass % is recovered, through distillation or a similar technique, from the eluate obtained through the elution step (A), which contains the by-produced carboxylic acid mixture, and at least a portion of the thus-recovered hydrous acetic acid is reused in liquid-phase oxidation reaction, or employed in the elution step (A) or in the below-described displacement step.
  • hydrous acetic acid having a water content of 20 mass % or more (preferably 20 to 70 mass %, more preferably 25 to 50 mass %, much more preferably 25 to 40 mass %), hydrous acetic acid which contains heavy metal ions and bromide ions, and which can be reused, as it is, in liquid-phase oxidation reaction (hereinafter the thus-obtained hydrous acetic acid may be referred to as a “recovered catalyst liquid”) can be produced.
  • a condensate (water content: 20 to 50 mass %) recovered in liquid-phase oxidation reaction by means of a reflux condenser attached to the reactor may be employed in the elution step (B) as hydrous acetic acid.
  • the pyridine-ring-containing chelate resin which has undergone the elution step (B) is brought into contact with a displacement liquid; i.e., hydrous acetic acid having a water content of 1 to 15 mass % (preferably 1 to 14 mass %, more preferably 1 to 9 mass %), to thereby regenerate the pyridine-ring-containing chelate resin.
  • a displacement liquid i.e., hydrous acetic acid having a water content of 1 to 15 mass % (preferably 1 to 14 mass %, more preferably 1 to 9 mass %)
  • the displacement step the water content of hydrous acetic acid present around the chelate resin is reduced to a level equal to the water content of the displacement liquid, so that heavy metal ions and bromide ions are rapidly adsorbed on the chelate resin in the subsequent adsorption step.
  • the displacement step is not performed, since the chelate resin layer is surrounded by hydrous acetic acid having a high water content immediately after the elution step (B), in the adsorption step, adsorption efficiency of catalyst components is reduced at an early stage of exposure of the chelate resin to the mother liquor, and percent recovery of the catalyst components is reduced, resulting in an economic disadvantage.
  • hydrous acetic acid having a water content of 1 to 15 mass % and containing bromide ions in an amount of 1 to 1,000 mass ppm is employed as a displacement liquid.
  • acetic acid water content: 4 to 12 mass %, bromide ion content: 1 to 50 mass ppm
  • acetic acid water content: 4 to 12 mass %, bromide ion content: 1 to 50 mass ppm
  • FIG. 1 shows an exemplary process for producing isophthalic acid.
  • the present invention is not limited to the process shown in FIG. 1 .
  • a mixture of raw materials (a m-phenylene compound, a heavy metal compound, a bromine compound, and hydrous acetic acid) is fed through a conduit 22 to a reactor 1 , and liquid-phase oxidation reaction is performed in the presence of a molecular-oxygen-containing gas.
  • the reaction product is in the form of slurry obtained through crystallization of a portion of crude isophthalic acid.
  • the reaction product is subjected to pressure reduction and cooling through flash evaporation in several stages in a crystallization step 2 , followed by separation by means of a solid-liquid separator 3 , to thereby yield a cake of crude isophthalic acid crystals.
  • the thus-obtained cake is transferred through a conduit 11 .
  • the mother liquor recovered through separation by means of the solid-liquid separator 3 is fed via a conduit 12 to a mother liquor receiving tank 4 , and hydrobromic acid is fed from a hydrobromic acid tank 6 through a conduit 13 to the mother liquor receiving tank 4 , to thereby appropriately regulate the bromide ratio of the mother liquor.
  • the mother liquor is caused to pass through conduits 14 and 15 , and then subjected to the adsorption step; i.e., the mother liquor is introduced to a pyridine-ring-containing chelate resin column 5 through the top of the column and caused to pass therethrough.
  • a substance which is not adsorbed on the pyridine-ring-containing chelate resin is discharged from the bottom of the column, and then purged via conduits 16 and 17 .
  • the substance is appropriately subjected to, for example, distillation for recovery of hydrous acetic acid, and the thus-recovered hydrous acetic acid is transferred (for reuse) to a raw material tank 10 or a tank 7 for storing hydrous acetic acid having a water content of about 14 mass %.
  • the pyridine-ring-containing chelate resin which has undergone the adsorption step is subjected to the elution step (A). Specifically, hydrous acetic acid having a water content of about 14 mass % is fed from the tank 7 through a conduit 18 and the conduit 15 , and introduced to the pyridine-ring-containing chelate resin column 5 through the top of the column and caused to pass therethrough. An eluate containing a by-produced carboxylic acid mixture is discharged from the bottom of the column, and then purged via the conduits 16 and 17 .
  • the eluate is appropriately subjected to, for example, distillation for recovery of hydrous acetic acid, and the thus-recovered hydrous acetic acid is transferred (for reuse) to the raw material tank 10 or the tank 7 for storing hydrous acetic acid having a water content of about 14 mass %.
  • the elution step (B) is carried out. Specifically, hydrous acetic acid having a water content of about 35 mass % is fed from a tank 8 through a conduit 19 and the conduit 16 , and introduced to the pyridine-ring-containing chelate resin column 5 so as to pass therethrough for elution of heavy metal ions and bromide ions adsorbed on the pyridine-ring-containing chelate resin.
  • the thus-recovered catalyst liquid is transferred through a conduit 20 to an intermediate tank 9 .
  • the recovered catalyst liquid is fed through a conduit 21 to the raw material tank 10 , and reused as a catalyst for liquid-phase oxidation reaction.
  • the displacement step is carried out. Specifically, hydrous acetic acid having a water content of about 14 mass %, serving as a displacement liquid, is fed from the displacement liquid tank 7 through the conduit 18 and the conduit 15 , and introduced to the pyridine-ring-containing chelate resin column 5 so as to pass therethrough. The resultant eluate is purged via the conduits 16 and 17 . The eluate is appropriately subjected to, for example, distillation for recovery of hydrous acetic acid, and the thus-recovered hydrous acetic acid is transferred (for reuse) to the raw material tank 10 or the tank 7 for storing hydrous acetic acid having a water content of about 14 mass %. After completion of the displacement step, the aforementioned adsorption step may be carried out.
  • a pyridine-ring-containing chelate resin prepared through the following procedure: an acetic acid solution (200 mL) containing 10 mass % hydrobromic acid was caused to pass through a pyridine-ring-containing chelate resin [“Sumichelate (registered trademark) CR-2” (trade name, product of Sumitomo Chemical Co., Ltd.)] so as to prepare a bromide-type pyridine-ring-containing chelate resin, and excess hydrobromic acid was rinsed out the chelate resin with an acetic acid solution having a water content of 14 mass %.
  • Heavy metal ion concentration was determined by means of an atomic absorption spectrophotometer having the following specification.
  • Determination method An appropriate amount of a sample is placed in a 100-mL glass container (weight of the sample is measured by means of a balance), and the sample is diluted with pure water and 20 mass % hydrochloric acid (constant boiling point, iron-free) for accurate analysis (about 2 mL) so that the concentration of heavy metal ions to be measured is about 1 ppm (the mass of the diluted sample is measured for determination of a dilution factor).
  • the heavy metal ion concentration of the diluted sample is determined on the basis of a calibration curve prepared by use of standard samples having heavy metal ion concentrations of 0 ppm, 1 ppm, and 2 ppm.
  • the heavy metal ion concentration of the undiluted sample is determined by multiplying the heavy metal ion concentration of the diluted sample by the dilution factor.
  • Bromide ion concentration was determined under the following conditions.
  • Titrator Automatic potentiometric titrator AT-510 (product of Kyoto Electronics Manufacturing Co., Ltd.) Titration liquid: 1/250 N aqueous silver nitrate solution
  • a Teflon (registered trademark) stirrer chip is placed in a 200-mL beaker, and an appropriate amount of a sample is placed therein (the mass of the sample is measured by means of a balance). Pure water is added to the beaker so that the volume of the liquid in the beaker is about 150 mL, and 60 mass % nitric acid (about 2 mL) is added thereto. Bromide ion concentration is determined through precipitation titration by means of the aforementioned automatic potentiometric titrator. ⁇ Method for Determining by-Produced Carboxylic Acid Mixture Concentration>
  • Percent recovery of cobalt ions was determined by calculating the ratio (%) of the amount of cobalt ions contained in a recovered catalyst liquid to that of cobalt ions contained in a mother liquor.
  • Percent recovery of manganese ions was determined by calculating the ratio (%) of the amount of manganese ions contained in the recovered catalyst liquid to that of manganese ions contained in the mother liquor.
  • Percent recovery of bromide ions was determined by calculating the ratio (%) of the amount of bromide ions contained in the recovered catalyst liquid to that of bromide ions contained in the mother liquor.
  • Percent inclusion of a by-produced carboxylic acid mixture was determined by calculating the ratio (%) of the amount of a phthalic acid compound or trimellitic acid compound contained in the recovered catalyst liquid to that of a phthalic acid compound or trimellitic acid compound contained in the mother liquor.
  • m-Xylene was subjected to liquid-phase oxidation reaction (reaction temperature: 200° C., reaction pressure: 1.62 MPa) by use of air in hydrous acetic acid having a water content of 9 mass % in the presence of cobalt acetate, manganese acetate, and hydrobromic acid, to thereby yield a slurry containing crude isophthalic acid.
  • reaction temperature 200° C.
  • reaction pressure 1.62 MPa
  • the slurry was subjected to a crystallization step, followed by pressure release and cooling to 100° C.
  • the isohpthalic acid was removed through solid-liquid separation with a glass filter, to thereby recover crude isophthalic acid crystals and a mother liquor of about 80° C.
  • the mother liquor was found to contain cobalt ions in an amount of 1,040 mass ppm, manganese ions in an amount of 1,010 mass ppm, bromide ions in an amount of 890 mass ppm, trimellitic acid compounds in an amount of 8,800 mass ppm, phthalic acid compounds in an amount of 4,100 mass ppm, and water in an amount of 13.9 mass %.
  • the bromide ratio of the mother liquor was found to be 0.31.
  • the above-preliminarily treated pyridine-ring-containing chelate resin (85 mL) was charged into a double-tube glass column. Hot water of 80° C. was circulated through a jacket of the pyridine-ring-containing chelate resin column, to thereby maintain the pyridine-ring-containing chelate resin at 80° C.
  • hydrous acetic acid having a water content of 35 mass % was introduced to the column through the bottom and caused to pass upward therethrough at a flow rate of 360 g/hour for 90 minutes [elution step (B)].
  • a displacement liquid hydroous acetic acid having a water content of 14 mass %) was introduced to the column through the top and caused to pass downward therethrough at the same flow rate as described above for 20 minutes [displacement step].
  • a cycle consisting of the adsorption step, the elution step (A), the elution step (B), and the displacement step (and return to the adsorption step) was repeated at 180 minutes/cycle.
  • a catalyst liquid recovered through the elution step (B) and containing cobalt ions, manganese ions, and bromide ions was reused as a catalyst for liquid-phase oxidation reaction.
  • Table 1 shows data of percent recovery of cobalt ions, manganese ions, and bromide ions, and percent inclusion of phthalic acid compounds and trimellitic acid compounds, as determined by use of a catalyst liquid recovered on day 4 of the experiment.
  • m-Xylene was subjected to liquid-phase oxidation reaction (reaction temperature: 200° C., reaction pressure: 1.62 MPa) by use of air in hydrous acetic acid having a water content of 9 mass % in the presence of cobalt acetate, manganese acetate, and hydrobromic acid, to thereby yield a slurry containing crude isophthalic acid.
  • reaction temperature 200° C.
  • reaction pressure 1.62 MPa
  • the slurry was subjected to a crystallization step, followed by pressure release and cooling to 100° C.
  • the isophthalic acid was removed through solid-liquid separation with a rotary vacuum filter, to thereby recover crude isophthalic acid crystals and to recover a mother liquor of about 80° C.
  • the mother liquor was found to contain cobalt ions in an amount of 500 mass ppm, manganese ions in an amount of 490 mass ppm, bromide ions in an amount of 430 mass ppm, trimellitic acid compounds in an amount of 4,600 mass ppm, phthalic acid compounds in an amount of 2,200 mass ppm, and water in an amount of 10.7 mass %.
  • the bromide ratio of the mother liquor was regulated to 1.11 by adding hydrobromic acid to the mother liquor.
  • a pyridine-ring-containing chelate resin “REILLEX (registered trademark) 425 Polymer” (trade name, product of Reilly) which had been preliminarily treated in a manner similar to that described above (80 mL) was charged into a double-tube glass column. Hot water of 80° C. was circulated through a jacket of the pyridine-ring-containing chelate resin column, to thereby maintain the pyridine-ring-containing chelate resin at 80° C.
  • hydrous acetic acid having a water content of 35 mass % was introduced the column at the bottom and caused to pass upward therethrough at a flow rate of 360 g/hour for 70 minutes [elution step (B)].
  • a displacement liquid water content: 8 mass %) was introduced to the column through the top and caused to pass downward therethrough at the same flow rate as described above for 20 minutes [displacement step].
  • a cycle consisting of the adsorption step, the elution step (A), the elution step (B), and the displacement step (and return to the adsorption step) was repeated at 180 minutes/cycle.
  • Hydrous acetic acid (water content: about 8 mass %) was recovered, through distillation, from a residual mother liquor obtained through the adsorption step, an eluate obtained through the elution step (A), and a displacement liquid employed in the displacement step, and the thus-recovered acetic acid was reused as hydrous acetic acid in liquid-phase oxidation reaction, as hydrous acetic acid in the elution step (A), and as a displacement liquid in the displacement step.
  • a catalyst liquid recovered through the elution step (B) and containing cobalt ions, manganese ions, and bromide ions was reused as a catalyst for liquid-phase oxidation reaction.
  • Table 9 shows data of percent recovery of cobalt ions, manganese ions, and bromide ions, and percent inclusion of phthalic acid compounds and trimellitic acid compounds, as determined by use of a catalyst liquid recovered on day 90 of the experiment.
  • Example 10 The experiment was performed in the same manner as employed in Example 8, except that the recovered mother liquor was heated to 90° C., and then subjected to the adsorption step.
  • Table 10 shows data of percent recovery of cobalt ions, manganese ions, and bromide ions, and percent inclusion of phthalic acid compounds and trimellitic acid compounds, as determined by use of a catalyst liquid recovered on day 10 of the experiment.
  • Example 11 The experiment was performed in the same manner as employed in Example 8, except that the recovered mother liquor was cooled to 40° C., and then subjected to the adsorption step.
  • Table 11 shows data of percent recovery of cobalt ions, manganese ions, and bromide ions, and percent inclusion of phthalic acid compounds and trimellitic acid compounds, as determined by use of a catalyst liquid recovered on day 4 of the experiment.
  • Example 12 The experiment was performed in the same manner as employed in Example 8, except that the recovered mother liquor was heated to 100° C., and then subjected to the adsorption step.
  • Table 12 shows data of percent recovery of cobalt ions, manganese ions, and bromide ions, and percent inclusion of phthalic acid compounds and trimellitic acid compounds, as determined by use of a catalyst liquid recovered on day 10 of the experiment.
  • trimellitic acid compounds is reduced to 43% or less, and percent inclusion of phthalic acid compounds is reduced to 14% or less.
  • percent inclusion of trimellitic acid compounds is reduced to 20% or less, and percent inclusion of phthalic acid compounds is reduced to 10% or less.
  • the bromide ratio of a mother liquor is regulated to 0.9 to 2.1 before the adsorption step (Examples 2 to 4) or when the time of the elution step (A) (i.e., Q/A) is regulated as described in Example 5
  • percent inclusion of trimellitic acid compounds and phthalic acid compounds is reduced, as compared with the case of Example 1.
  • Example 6 or 7 percent recovery of heavy metal ions is somewhat increased, as compared with the case of Example 2.
  • percent recovery of heavy metal ions is increased, and percent inclusion of trimellitic acid compounds and phthalic acid compounds is reduced.
  • percent inclusion of trimellitic acid compounds is 58%, and percent inclusion of phthalic acid compounds is increased to 35%. That is, this method encounters difficulty in continuously performing liquid-phase oxidation reaction over a long period of time while reusing recovered catalyst components.
  • the present invention realizes economically advantageous and long-term stable production of isophthalic acid.
  • Isophthalic acid produced through the method of the present invention can be employed as an intermediate of polymers such as unsaturated polyester resin, alkyd resin, modified polyester fiber, heat-resistant polyamide, and isophthalic-acid-modified co-polyester resin.

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US20110213180A1 (en) * 2006-12-20 2011-09-01 Mitsubishi Gas Chemical Company, Inc. Process for production of isophthalic acid
US8957247B2 (en) 2010-02-19 2015-02-17 Toyobo Co., Ltd. Pretreatment method for chelate resin having pyridine ring used for collecting catalyst in aromatic carboxylic acid production process
US9347112B2 (en) 2010-02-19 2016-05-24 Mitsubishi Gas Chemical Company, Inc. Pretreatment method for chelate resin having pyridine ring used for collecting catalyst in terephthalic acid production process

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EP2634168B1 (en) 2010-10-26 2019-12-11 Mitsubishi Gas Chemical Company, Inc. Crossflow type filtering operation method using ceramic filter
WO2012057156A1 (ja) 2010-10-26 2012-05-03 三菱瓦斯化学株式会社 セラミックフィルターを用いるクロスフロー方式による濾過運転方法
JP5685954B2 (ja) * 2011-01-21 2015-03-18 三菱瓦斯化学株式会社 芳香族カルボン酸の製造方法

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US9347112B2 (en) 2010-02-19 2016-05-24 Mitsubishi Gas Chemical Company, Inc. Pretreatment method for chelate resin having pyridine ring used for collecting catalyst in terephthalic acid production process

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