Production of Acetone

5. 1 MANUFACTURING PROCESSES dimethyl ketone is pissd directly or indirectly by propylene. Early surgical processes for the manufacture of propanone were base on the thermal decomposition of atomic number 20 acetate rayon or the carbohydrate unrest of corn starch or molasses. The piece availability of propylene in the mid-sixties led to r come ines based on the de henryation of isopropyl alcoholic drink or cumene per oxidisation. (1) By Cumene Oxidation (Hock Process). propylene is added to benzene 71-43-2 to form cumene 98-82-8, which is wherefore oxidised by air to cumene hydroperoxide, and cleaved in the bearing of an acid gas pedal like zeolite. phenylic acid 108-95-2 and propanone 67-64-1 produced in the process be vulcanised by distillation. Ratio of phenol to dimethyl ketone is 10. 6. (2) By De heat contentation of 2-proponal The hydration of propene 115-07-1 gives 2-propanol 67-63-0, which is therefore dehydrogenated to dimethyl ketone. In the unit of measurement of measuremente States a C3 current containing 40 60 % propene is utilize for the manufacture of 2-propanol. A life-sized number of catalysts for 2-propanol dehydrogenation pass water been studied, including dogshit, atomic number 30, and lead metals, as well as metal oxides, e. g. , zinc oxide, copper oxide, chromium-activated copper oxide, manganese oxide, and magnesium oxide.Inert supports, such as pumice, may be utilise. CH3CH=CH2 CH3CH(OH)CH3 CH3COCH3 +H2 (3) By catalytic oxidisation of Propene (Wacker-Hoechst). The process is analogous to the oxidation of ethylene to ethanal by theWacker process. The catalyst solution typically contains 0. 045M palladium (II) chloride, 1. 8M hog (II) Chloride, and acetic acid. The reaction normally is carried out in two alternating plays. In the first stage, air is used to change the metal ions to the +2 oxidation state. In the second, air is distant and propene added.Palladium (II) oxidizes propene, and the resulting Palladium (I) is re change by the pool of copper (II). Besides propionaldehyde, chlorinated carbonyl compounds and carbon dioxide besides be create. acetone and the spin-offs ar removed from the catalyst solution by splashiness evaporation with steam and clear upd by componental distillation. A mixture of acetone (92 % selectivity) and propionaldehyde (2 4 % selectivity) is produced. CH3CH=CH2 + ? O2 CH3COCH3 + CH3CH2CHO (4) By oxidation of p-Disisopropyl Benzene (Goodyear Process).Acetone is coproduced with hydroquinone 123-31-9 from p-diisopropylbenzene 100-18-5 in a process analogous to the phenol acetone outpution from cumene. In the Goodyear process p-diisopropylbenzene is oxidized by oxygen in the presence of caustic. The p-diisopropylbenzene dihydroperoxide 3159-98-6 formed is crystallized and washed with benzene. It is then dissolved in acetone and cleaved to hydroquinone and acetone in the presence of sulfuric acid. near the acid is neutralized with ammonia a nd the ammonium ion sulfate formed is filtered. Acetone is find by distillation from the reaction mixture. 5) By distillation of Calcium Acetate. Manufacture of Acetone from Acetate of Lime, etc. Acetone is produced commercially by the dry distillation of various(a) acetates, atomic number 20 acetate (commercial grey acetate of lime) or barium acetate be generally used. The single acetate is usually employed, although mixtures of two acetates have been recommended. Grey calcium acetate usually contains close 80 per cent calcium acetate, the re importanting 20 per cent consisting of urine and various impurities, including minor quantities of calcium formate and propionate as well as salts of other organic acids.Calcium acetate when heated at a temperature of about 380 C. decomposes, giving acetone and a equilibrium of calcium carbonate, entirely at the alike time the accompanying calcium salts march as impurities also react and acetaldehyde and various higher ketones be formed together with the condensation convergences. In auxiliary other impurities (such as dumasin) and tar-like bodies are formed. Ca(CH? -COO)? CH? -CO-CH? + CaCO? (6) By fermentation of Corn Products by selected Bacteria. The process was started during World War II to go out acetone needed for the manufacture of cordite.The pop off run plant in the United States (Publicker Industries) closed in 1977. The fermentation of cornmeal or molasses by various members of the clostridia genus yields a mixture of 1-butanol, acetone, and ethanol in 2 % overall concentration. The products are recovered by steam distillation and then fractionated. 5. 2 SELECTION OF PROCESSES Sr NoProcessesParameterCatalystAdvantages/ Disadvantages 1Cumene Oxidationoutput signal- 40% Selectivity- 90% 1)For Cumene hydroperoxide temporary worker- 120 0C mechanical press- 1 atm 2) For acetone temporary worker- 60-65 0CAcid catalyst like zeoliteAdvantage- Valuable main product phenol Disadvantage ) high op erating personify. 2) Acetone is as a byproduct. 2Dehydrogenation of 2-proponalYield- 90% Selectivity- 98% Temp- 300-500 0C squelch- 3 atm Dehydrogenation Catalyst- ZnO, CuAdvantages- 1) The master(a) advantage of this process is that the acetone produced is ingenuous from trace aromatic compounds, particularly benzene. 2) less(prenominal) operating cost 3) Valuable byproduct Hydrogen which is 99% pure. 4) High Yield 3Catalytic oxidation of PropeneYield- 97-99% Selectivity-92% Temp- 140 0C impel- 14 atmPalladium Chloride Cupric ChlorideAdvantage- 1) Single stageDisadvantages- 1) High capital & operating cost. 2) corrosion problem. 4Oxidation of p-Di-isopropyl BenzeneYield- 20% Temp- 80-90 0CSulfuric acidDisadvantage 1) Higher operating cost. 2) Acetone is as a byproduct. 3) dishonor yield 5Distillation of Calcium AcetateYield- 75% Temp- 380 0C Disadvantage 1) Higher operating cost 2) discredit yield 6Fermentation processYield- 28-30% Temp- 35-450CClostridium Madisonii Vac teriaDisadvantages 1) Lower yield. 2) Higher processing cost out-of-pocket to increase in price of petrochemical guidestock which is used for extracting the acetone.On the above discussion between various methods we are choosing the IPA route to produce Acetone. 5. 3 PROCESSES DESCRIPTION The production of acetone is divided in two parts. 1)Production of IPA through Feed drum is a assortment of tank used for the concoction of the reprocess sprout and throw stream. Recycle stream concentration was untrue to be said(prenominal) with the feed stream. The temperature of the feed stream is false to be 25 0C at 2 bar pressure, which is imitation to be constant. The temperature of cycle stream was calculated as 111. 5 0C. The temperature of the leave stream was calculated as 32. 9 0C, by the energy equipoise around feed drum. In the vaporizer melted salt was used for heating. The temperature at the catch of the unit is the temperature of the mixture passing the feed drum , which is 32. 89 0C. And the going temperature is the smatter picture temperature of the mixture, which is 109. 5 0C. The pressure is 2 bars, and fancied to be constant. Since the temperature loss the vaporizer is non passable for the reaction a pre-heater was used. The unit is working(a) at 2 bars, and sour to be constant. The entrance and leaving temperatures are 109. 50 0C and 325 0C.The reactor was the starting request for the calculations. The temperature value for the come in and leaving streams were ready from literature, which are 325 0C and 350 0C, respectively. The reaction taken place interior is endothermic, for this reason the reactor has to be heated. For heating, liquefied salt was used. The pressure is 1. 8 bar, and fabricated to be constant. The entrance temperature of the cooler is 350 0C and leaving is 94. 70 0C. For temperature reduction, water was used. Instead of water a refrigerant may be used. Better results may get. hardly since it cost too much, it wasnt chosen as the cooling material.From the temperature values its easily seen that the load is on the cooler not on the condenser, for this process. But in naive realism the unit cannot cool that much, and the load is for the most part on the condenser. In this process, the mixture cooled big money to its dew point. The pressure is 1. 5 bar, and fictive to be constant. The temperature of the entering stream is the dew point and the leaving temperature is the bubble point of the mixture. In the condenser water was used as cooling material. In the calculation of the dew and bubble points Antoine equality was used. Trial and error was used with the attention of Excel.The mixture includes acetone, i-propyl-alcohol, water and hydrogen. But hydrogen was not taken into reflexion in the calculations. Since the condensation temperature of hydrogen is very low, it is not condense in the condenser. It stays in this for this reasons it has no effect on bubble and dew point calculations. Also since it does not cloak the temperature calculations its not taken into consideration on mole and mass fraction calculations. The leaving and entering temperatures are 94. 70 0C and 81 0C, respectively. The pressure is 1. 5 bar, and assumed to be constant.Flash unit was assumed to be isothermal, for this reason temperature was not changed. It is 81 0C in the entrance and exit. The pressure is 1. 5 bar, and assumed to be constant. By running and error method, (V / F) value was found to be 0. 2. The entrance temperature of the unit is the bubble point of the mixture, but if it was its dew point the (V/F) value would be much higher. Scrubber was assumed to be adiabatic. The temperature of water entering the unit was assumed to be 25 0C. The temperature of the off gas, including hydrogen and a very piddling measure of acetone, was assumed to 70 0C.But this confidence is too high, a lower temperature should have been assumed, since a lot of water is used in the un it. It should have been around 40 0C 50 0C. The temperature of the leaving stream was found to be 28. 10 0C. The pressure of the unit is 1.. 5 bar, and assumed to be constant. The streams leaving the scrubber and flash unit are mixed together before entering the acetone column. The temperature leaving the flash unit and scrubber are 81 0C and 28. 10 0C, respectively. The temperature of the mixture was found to be 45 0C. This result was getting by employ energy balance around the mixing point.The acetone column is used to separate the acetone from the mixture. The entrance temperature is 45 0C. The leaving temperatures for the top and tail product are 102. 3 and cv, respectively, which are the bubble and dew points. expire product of the unit includes acetone i-propyl-alcohol and 99wt% of the product is acetone. This amount is assumed to be the desired acetone production rate, which is 115000 ton/year. From the bottom i-propylalcohol water and a very little amount of, 0,1 %, ace tone is discharged. The pressure is 1. 1 bar, and assumed to be constant. In the distillation column, i-propyl-alcohol and water are separated.The entrance temperature is 105 0C. The leaving temperatures of the top and bottom products are both 111. 50 0C. The top product is recycled to the feed drum. For this reason its assumed to have the same concentration with the feed stream. But in reality a very little amount of acetone exists in the stream. Its calculated but neglected on the recycle stream calculations. The bottom product is assumed to be pure water and its propel away. Since its temperature is very high it cannot be recycled to the scrubber. But if a cooler is used, a recycle can be used. The pressure is 1. 1 bar, and assumed to be constant.