VINYL ACETATE PROCESS ECONOMICS PROGRAM I. Report No. 15A. Supplement A. by YEN-CHEN. June A private report by the

Transcription

1 Report No. 15A VINYL ACETATE Supplement A by YEN-CHEN YEN June A private report by the PROCESS ECONOMICS PROGRAM I STANFORD RESEARCH INSTITUTE MENLO I PARK, CALIFORNIA

2 CONTENTS 1 INTRODUCTION......, SUMMARY... 3 General Aspects... 3 Technical Aspects INDUSTRY STATUS , VINYL ACETATE FROM ETHYLENE BY VAPOR PROCESSES Chemistry Review of Processes Catalyst Reactants Reactor 34 Processes Without Recovery of Vinyl Acetate... 1'.. 35 Vinyl Acetate from Ethylene and Process Description Process Discussion Cost Estimates Vinyl Acetate from Ethylene Feed and Acetic Acid Formed in Process Process Description Process Discussion Cost Estimates Vinyl Acetate from Ethylene Feed and Acetic Acid Formed in Process from Acetaldehyde Feed Comparison of Variations of Ethylene Vapor Process VINYL ACETATE FROM ETHYLENE BY LIQUID PROCESSES Chemistry Review of Processes Catalyst Vinyl Acetate/Acetaldehyde Ratio One-Stage or Two-Stage Reaction Product in Gas or Liquid Reactors Separation and Purification of Vinyl Acetate... Recovery of Spent Catalyst, Removal of Precipitates and 89 High-Boiling Impurities V

3 CONTENTS 5 (continued) Vinyl Acetate from Ethylene by Single-Stage Liquid Process,. 93 Process Description,.,.,....,,,..,...,. 93 Process Discussion ,. 107 Cost Estimates....,....,, Modification--Using a Catalyst System Containing No Halide. 116 Modification--Without Acetaldehyde Production Modification--Another Way To Recover Catalyst,..,., Process Description Process Discussion...., Cost Estimates., VINYL ACETATE FROM ETHANE Process Description Process Discussion Cost Estimates VINYL ACETATE FROM ACETYLENE BY VAPOR PROCESS,...,.., 155 Chemistry , Review of Processes Evaluation of the Process.,...., VINYL ACETATE BY OTHER PROCESSES Acetaldehyde Process Vinyl Acetate from Vinyl Chloride Vinyl Acetate from Ethyl Acetate Vinyl Acetate from Ethylene by Oxidation by Peracetic Acid with a Selenic Oxide Catalyst MANUFACTURE OF OTHER VINYL ESTERS.....,.., Acetylene Process Ethylene Process ,...., 169 Transvinylation...., Vinyl Propionate from Acetylene by Vapor Process.....,. 170 Vinyl Ester of Versatic 63 Acid from Acetylene by Liquid Process , Vi

4 CONTENTS APPENDIX A DESIGN AND COST BASIS APPENDIX B PHYSICAL DATA APPENDIX C SPECIFICATIONS REFERENCES PATENT REFERENCES BY COMPANY Vii

5 ILLUSTRATIONS B ,.. 43 Acetic Acid Feed Production Costs at Different Production Levels. 56 : Hydrolysis Section Production Costs at Different Production Levels.., Vinyl Acetate from Ethylene by Single-Stage Liquid Process. 99 Vinyl Acetate from Ethylene by Single-Stage Liquid Process Production Costs at Different Production Levels Vinyl Acetate from Ethylene by Single-Stage Liquid Process: Alternative Way To Regenerate Catalyst and To Remove High Boiling Impurities.., Production Costs at Different Production Levels,.., Vinyl Acetate from Ethane...., Vinyl Acetate from Acetylene in Vapor Phase Production Costs at Different Production Levels, Vinyl Ester of Versatic Acid from Acetylene..,., Relative Volatilities Between Components of the System Acetic Acid-Vinyl Acetate-Acetaldehyde , 190 IX

6 TABLES Manufacture of Vinyl Acetate Summary of Cost Estimates Vapor Process for Vinyl Acetate from Ethylene and Summary of Cost Estimates for Variations in Design..,. 8 Manufacture of Other Vinyl Esters. Summary of Cost Estimates , Vinyl Acetate Producers in the United States Vinyl Acetate Producers in Japan Vinyl Acetate Producers in Europe., , Vinyl Acetate Producers in Regions Other than the United States, Europe, and Japan,....., Vinyl Acetate from Ethylene by Vapor Processes Patent Summary Recovery and Purification of Vinyl Acetate Patent Summary Major Process Equipment and Utilities Summary., Stream Flow Changes in Major Process Equipment for 10% COs in Recycle Gas Changes in Major Process Equipment for 30% COa in Recycle Gas Total Capital Investment Production Costs Xi

7 TABLES Major Process Equipment and Utilities Summary.,.,.., 59 Stream Flows , , 63 Total Capital Investment ,.., Production Costs.....,..,...,,.,., Vinyl Acetate from Ethylene by Single-Stage Liquid Processes with Redox Salts Patent Summary..,.., , es with Redox Salts Patent Summary ,.. 83 Vinyl Acetate from Ethylene Oxidation with Oxygen by Liquid Processes Without Redox Salts Patent Summary.,,....,,......,,,,.,. 87 Vinyl Acetate from Ethylene by Liquid Processes: Treatment of Spent Catalyst Solution and Preparation of Catalyst Solution Patent Summary ,......, Vinyl Acetate from Ethylene by Single-Stage Liquid Process Major Process Equipment and Utilities Summary..,,.., Vinyl Acetate from Ethylene by Single-Stage Liquid Process Stream Flows , Vinyl Acetate from Ethylene by Single-Stage Liquid Process Total Capital Investment Vinyl Acetate from Ethylene by Single-Stage Liquid Process Production Costs...,,.....,., Vinyl Acetate from Ethylene by Single-Stage Liquid Process: Alternative Way To Regenerate Catalyst and To Remove High-Boiling Impurities Major Process Equipment and Utilities Summary: Catalyst Regeneration Section , Xii

8 TABLES Vinyl Acetate from Ethylene by Single-Stage Liquid Process: Alternative Way To Regenerate Catalyst and To Remove High-Boiling Impurities Capital Investment: Catalyst Regeneration Section., Major Process Equipment and Utilities Summary..., Stream Flows Total Capital Investment Production Costs..., ,. 137 Vinyl Acetate from Ethane Major Process Equipment and Utilities Summary...., Vinyl Acetate from Ethane Stream Flows, ,. 149 Vinyl Acetate from Ethane Total Capital Investment ,, 152 Vinyl Acetate from Ethane Production Costs , Vinyl Acetate from Acetylene in Vapor Phase Patent Summary Vinyl Acetate from Acetylene in Vapor Phase Total Capital Investment.,......, Vinyl Acetate from Acetylene in Vapor Phase Production Costs Vinyl Esters Other than Vinyl Acetate from Acetylene Patent Summary Vinyl Esters by Transvinylation and Vinyl Acetate Patent Summary., , ,. 173 Vinyl Propionate from Acetylene by Vapor Process Total Capital Investment Vinyl Propionate from Acetylene by Vapor Process Production Costs Xiii

9 TABLES 9.5 Vinyl Ester of Versatic Acid from Acetylene Major Process Equipment and Utilities Summary Vinyl Ester of Versatic Acid from Acetylene Stream Flows..,.,, ,..., Vinyl Ester of Versatic Acid from Acetylene Total Capital Investment , Vinyl Ester of Versatic Acid from Acetylene Production Costs.,.,..., ,. 183 xiv