Energy Efficiency & Renewable Energy
INDUSTRIAL TECHNOLOGIES PROGRAM Millisecond Oxidation of Alkanes Novel Process Will Replace Conventional Acrylic Acid/Propylene Production Processes
Acrylic acid is one of the fastest growing a novel millisecond oxidation process for Benefits for Our Industry and Our commodity chemicals, produced at a rate of conversion of propane to propylene and acrylic Nation 7.5 billion pounds per year, with worldwide acid. This process combines highly active demand growing at 4 percent annually. It is catalysts with an autothermal hybrid reactor at Autothermal oxidation for conversion of derived from propylene, which is currently relatively short contact times for the selective propane to propylene and acrylic acid promises produced from naphtha and liquefied petroleum oxidation of propane. Autothermal oxidation energy savings of 20 trillion Btu per year gas in energy-intensive steam crackers and promises to reduce the energy intensity of by 2020. In addition to reducing energy fluidized catalytic cracking units. While conventional propylene and acrylic acid consumption, this technology will reduce researchers have investigated more efficient production methods. This new process will manufacturing costs by up to 25 percent, and ways of producing acrylic acid directly, none also reduce undesirable secondary reactions reduce CO2, SOX, and NOX emissions. as of yet have been commercially feasible. found in conventional processing such as the formation of hydrocarbons and carbon Rohm and Haas, BASF Catalysts, and oxides. University of Connecticut seek to develop Applications in Our Nation’s Industry
Autothermal oxidation will find initial application in the conversion of propane to propylene and acrylic acid. Reducing the manufacturing cost of acrylic acid, a commodity chemical, will also positively impact a variety of downstream products, including coatings and sealants, super- absorbent polymer applications, and detergent additives.
Schematic of short contact time reactor: single monolith channel with layered catalyst structure
Boosting the productivity and competitiveness of U.S. industry through improvements and environmental performance INDUSTRIAL TECHNOLOGIES PROGRAM
Project Description Progress and Milestones Project Partners
The overall objective of the project is to • Setup high-throughput evaluation reactor Rohm and Haas Company commercialize a production process for unit and develop analytical method Spring House, PA propylene and acrylic acid from propane using (completed) Principal Investigator: a catalytic auto-thermal oxydehydrogenation Dr. Dan Bors ([email protected]) • Demonstrate catalyst performance with a process operating at short contact times. yield greater than 20% propylene without BASF Catalysts productivity constraints (completed) Barriers Iselin, NJ • Demonstrate catalyst performance with Major barriers to be overcome include: a yield greater than 20% propylene with University of Connecticut • Low reactivity of the propane vs. commercial feed conditions (completed) Storrs, CT propylene; • Meet break-even catalyst performance • Poor catalyst properties including low or targets for propane to propylene unstable activity and unselective active (completed) sites that degrade desired products or carry • Meet catalyst performance equivalent of 5 out competing parallel reactions; and cents/lb incentive over current technology • Homogeneous gas phase oxidation • Establish minimum catalyst life reactions that are rapid, free radical- propagated mechanisms, which are highly Commercialization unselective. The project partners will collaborate to achieve Pathways the objectives of this project. Catalyst synthesis will take place at Rohm and Haas, BASF The project team will address the technical Catalysts and at University of Connecticut challenges of propane oxidation to propylene research facilities. The catalysts synthesized and/or acrylic acid by developing catalytic at these facilities will be evaluated in a high- systems using highly active catalytic materials throughput unit at BASF Catalysts, and the operating at short contact time. Researchers A Strong Energy Portfolio for a leading candidates will undergo a detailed will evaluate mixed metal oxide and nano- Strong America evaluation at Rohm and Haas. A pilot plant engineered catalyst systems to develop highly Energy efficiency and clean, renewable energy unit will be set up at Rohm and Haas and will active catalytic materials and couple these will mean a stronger economy, a cleaner be used to identify safe operating conditions and environment, and greater energy independence novel catalyst s with an autothermal process for investigate control issues. for America. Working with a wide array of state, selective oxidation. community, industry, and university partners, the U.S. Department of Energy’s Office of Energy Efficiency and Renewable Energy invests in a diverse portfolio of energy technologies.
February 2009
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