Professional Documents
Culture Documents
FROM
PENTANE
RICHARD L. KENYON AND
GORDON c. INSKEEP
Associate Editors
in collaboration with
FUNDAMENTAL CHEMISTRY
Amyl alcohols are esterified with acetic acid in the presence o& formaldehyde resins. It has been used successfully as the vola-
sulfuric acid catalyst to yield amy1 acetate and also some by- tile portion of hydraulic fluids, and recently in antibiotic recovery
product pentenes as an extractant.
CsHiiOH + HOAC +CsHii0-4~+ HzO Primary n-amyl alcohol, isobutylcarbinol, sec-butylcarbinol,
diethylcarbinol, and tert-amyl alcohol are separated by the frac-
CbHiiOH +CjHio + Hi0 tional distillation of the crude amyl alcohols. All the isomers are
used in various organic syntheses. Diethylcarbinol is used in
the manufacture of flotation agents for nonferrous ores.
By esterification of amyl alcohol with acetic acid, Sharples pro-
duces a mixture of the isomeric amyl acetates (11). Large vol-
umes of acetate are used as a penicillin extractant. It is also used
in nitrocellulose lacquer formulations, and small quantities are
CALCIUM CHLORIDE used in the food industry as a flavoring agent.
DEHYDRATOR The amyl chlorides are reacted with sodium hydrosulfide to
give a mixture of amyl mercaptans (13) which is used as a fuel
gas warning agent; one pound per million cubic feet of gas is the
CH LO R I N E usual concentration.
TO VAPORIZER Amyl meieaptan is a mixture of the various amyl isomers and
r----eA can be used as a starting material in the synthesis of organic sul-
fur compounds.
Amyl sulfide is a yellow liquid having the amyl group present in
its isomeric forms. I t is used in the preparation of sulfones, sulf-
oxides, and other organic sulfur compounds through addition
TRACK "SCALE reactions.
LINKED TO WEIGHING BEAM Although Sharples has been producing amylphenols since the
WHICH ACTUATES ALARM HORN.
early 1930's, until just recently the amyl group present was
Figtin. I . ( liloiiii(. t iilo.i<lirig *I~II;O~I either wholly or predominantly the tertiary isomer. The com-
mercial scale production of the secondary amylphenols by reac-
tion of the normal pentenes has been initiated by Sharples in the
The pentenes are used in alkylating phenol and naphthalene past 5 years
to form the corresponding amyl derivatives p-tert-Amylphenol (fd) is used in the preparation of pale-
colored, light-stable, oil-soluble resins and also as a n intermediate
for pharmaceuticals.
1STEAM ~ U D Ean
.sm€
m NEUTRALIZATION
AHD BITCH
MSTILLATION
tubc. Feed enters the bottom header and the effluent mixture
MIXED comes from the top header. The temperature in the digesters is
PENTENE
CONDENSER regulated by automatic control of the steam pressure in thr
heaters within a range of j=1O C.
Once this start-up has been effected, constant chaiging of amyl
PHENOL chloride is begun. The chloride enters digester 1 through a
1-inch-diameter pipe, 8 feet long, which is closed a t the end and
perforated with ‘/*-inch holes to fecd a spray of the chloride into
the reaction mixture. There are sufficient holes to be equivalent
YQRMA!.
to one and a half times the cross-sectional area of the inlet pipe.
WEIGH PENTENES Addition of caustic, a t the suction side of the circulatory pump,
TANKS is begun at a rate which n-ill maintain a c*oncentrationof sodium
hydroxide of not less than 0.570 in digester 2. The caustic
passes through concentric tube preheaters which are heated b y
the condensate from steam traps.
The feed of both amyl chloride and caustic is regulated by
means of pneumatic controllers ( 4 A ) which control the steam
pressure operating the positive displacement pumps on both feed
lines. The pumps operate with a steam pressure of about 150
pounds per square inch. Pressure in the digesters is limited by
COLUMN a pressure relief valve which blows into a condenser a t the pres-
ALKYL AT I ON sure limit. An alternate valve is maintained for checking pui-
AUTOCLAVE
poses.
Product distills from a take-off line leading from the top of
I I
c CONDENSER
digester 2 to a shell-and-tube condenser in which cold water
-m
I3-6-
DECANTER
WATER
DIAMYLENE
passes through the tubes. The alcohol mixture which contains
amyl alcohol, amyl chloride, amylene, and water flows from the
Londenser through a decanter, where a major portion of the water
is removed and sent to a stripper to recover the alcohol. At t h i s
point the organic portion of the reaction product mixture is only
about 3Oj, soluble in water and separation is relatively easy.
I IDiGESTER
The residue, or bottoms, in the digester consists of a brine
d m o s t saturated &ith sodium chloride and containing about
0.5% sodium hydroxide. This is continuously drawn off thc
CRUDE
AMYL PHENOLS
bottom of digester 2 through an automatic control valve ( S A )
TO BATCH
which is regulated by the specific gravity differential between tho
DISTILLATION cffluent brine and the reaction mixture in the digesters. A
check sample is constantly drained near the bottom of digester 2
within sight of the operator. The brine is milky, and the reaction
Figure 4. Flow Sheet for Production of mixture is dark. Visual indication is thus given if the brine level
Amylphenols falls below the safe point. The brine sample is analyzed regu-
larly by the operator to determine its alkalinity. The rate of
Hydrolysis. Amyl chloride (a mixture of primary, secondary, caustic feed is based on the alkalinity of the brine. A very small
make-up of oleic acid is added occasionally.
and tertiary chlorides) is transferred by positive displacement
”pumpsfrom storage to weighing tanks. These are steel tanks of If all the chloride and alcohol were depleted during the hy-
1000-gallon capacity, set on scales. As the chloride still contains drolysis there would remain a sticky mass which could not be
some traces of hydrogen chloride it is passed through a caustic, pumped. As a safeguard, a sample is taken from the pump oncr
scrubber before entering the digester. The scrubber is an un- every 2 hours; i t is acidified and steam distilled to determine the
packed tank. It is partially filled with 12y0 caustic from the amount of volatile material present. Another safeguard is a red
regular supply, and the chloride is pumped into the bottom to light for which electrical contact is maintained by the brine under
rise through the caustic. The scrubbing solution is checked a t pressure. If the paste gets into the pressure tap, the small line
intervals of approximately 3 hours. When its strength is reduced plugs up; this reduces the pressure on the electrical contact :tnd
to 4% sodium hydroxide, i t is drained-and the solution replen- turns off the light.
ished. The brine, which is drawn from digester 1, is discharged by
The hydrolysis of amyl chloride i s carried out in a pair of di- digester pressure t o a flash tank on the second floor, wherc thc
gesters, which are steel reaction vessels without packing or agita- small amount of low boiling organic material contained is flash-
tion, insulated with 2-inch magnesia blocks. Digester 1 is filled, distilled through a water-cooled condenser to a decanter and
a t start-up, with oleic acid, amyl chloride, and enough preheated thence to a column. The brine then goes to storage tanks. Some
12y0 caustjc solution to bring the entire reaction mixture to a of it is used to neutralize hydrogen chloride which comes off with
sodium hydroxide concentration of 3%. The mixture flows froin pentane vapors from the hydrochloric acid unit.
No. I through a n outlet near the bottom which is controlled by a The product which distills from the top of digester 2 is pumped
gate valve, through a heater, and into the top of digester 2. A from a receiver to a 26-plate bubble-cap column which is sparged
stream is pumped by centrifugal pump from the bottom of KO. with steam. This column operates under preksure of 26 pounds
2, through another heater, and enters the top of digester 1. per square inch. The low boiling organic material which is
The digester heaters are made of 2-inch pipe inside 3-inch flashed from the brine also goes to this column. The stream is
pipe and are designed as parallel hairpin turns feeding into com- introduced just below the middle of the column. Amylene is
mon headers. Because of its consistmcy, the reaction mixture is taken from the t o p of this column and passes through a shell-and-
referred to as the “paste.” The paste flows through the innci tube condensei. A portion is returned to the column as refluy,
December 1950 INDUSTR,IAL A N D E N G I N E E R I N G C H E M I S T R Y 2395
--
NORMAL PENTEN
INDUSTRIAL AND E N G I N E E R I N G CHEMISTRY
CONDENSER
n
HCI VENT
SCRUBBER
CORROSION
Vol.. 42, No. 12'
F-
satisfactorily workcd out.
II WA~ER
TO SEWER
Clark (6) pointed out that the dehydration
o f the pentane was originally attempted in
coke-packed touws. Because of the gradual
WATER a
disintegration of the coke and packing of the
RECOVEREO wetted coke, the towers required frrquent
TANKS PENTENES cleaning and replacement of packing. Thc
remedy found was the one that is still in usc
I I CONDEJNSER today-bubbling anhydrous hydrochloric acid
through the pentane.
By rarefully maintaining anhydrous con-
ditions, it is possihle t o use carbon steel
equipment for the chlorination. A carbon film
-
c
COLUMN
forms in the Venturi mixer and undoubtedly
serves a s an effective protective coating.
Where the aqueous hydrochloric acid must
be handled, ceramic , resin-impregnated as-
bestos, and rubber-lined equipment is suc-
cessfully used. More expensive metals such
as tantalum have been considered, but an
economic balance of their high initial cost
against the replacement costs of the present
materials does not indicate that use of such
metals would be advisable.
Corrosion in the KO. 1 digester is negligible
because the unit is always full of liquid. In
the No. 2 digester, which is operated with a
vapor chamber, the corrosion is evident. The
possibility of using a different type material
for construction of the upper section is being
considered.
The scrubber for vented hydrogen chloride
vapors is a barrel-like structure made entirely
of wood and containing several perforatcd
Figure 5. Flow Sheet for Production of A m y l Naphthalenes plates.
Corrosive conditions in the preparation of
phenol derivatives arc met by the use of glass-
crude mixture in the autoclave is discharged to a batch still lined equipment and nickel-clad autoclaves. Stainless steel
where the hydrogen sulfide and a portion of the pentenes are dis- equipment is used €or handling distilled amylphenols because
tilled off. The hydrogen sulfide is absorbed in two caustic scrub- iron would cause discoloration of the product.
bers forming sodium hydrosulfide which is used in subsequent Some of the important pieces of cquipment along with the inn-
batches. The crude amyl mercaptans are steam distilled in this terials of construction arc listed in Tahlc V.
still separating them from the amyl sulfides and disulfides. The
SAFETY
residue in the still is separated into two layers; the lower aqueous
layer is disposed of with no subsequent treatment and the upper With' large quantities of flammablc, volatile, and skin-corrosive
sulfide layer is sent to storage. The crude amyl mercaptans arc materials as well as toxic gases to contend with, attention t o
sent to a second still where the last traces of hydrogen sulfide and safety is particularly important. Safety systems and devices
pentenes are removed. The charge is then aeeotropicab dried designed specifically for the process are found throughout thc
and the amyl mercaptans are separated from ethanol,. amyl plant.
chloride, amyl alcohol, and amyl sulfides. Fire prevcntion and fire fighting are planned in great detail.
Control of odor is the biggest problem in this process. All All persons entering the plant are required to surrender matches
vents from the scrubbers and tanks are connected to a header and smoking is not tolerated in any of the danger areas. Non-
which leads to a flare. This flare handles all hydrogen sulfide sparking shoes are worn by all operators in the fire hazardous
and amyl mercaptan vapors. Aqueous discharges are chlorin- areas; toe or heel plates are expressly prohibited.
ated before dropping t o the sewer. Chlorination converts the Emergency steam hoses are located a t convenient points
odorous mercaptans and sulfides to sulfoxides and sulfones. throughout the plant. Ininiediatcly on spillage of any flammable
The blending room, where open streams of mercaptans are pres- material, the area is blanketed with steam to prevent fire while
ent, is ventilated b y an exhaust blower which discharges through the material is being cleaned up. Instructions are issued to all
a n activated charcoal tower. By constant vigilance, escaping opwators pointing out the danger of throwing any clcctrical
odors from this process are kept to a minimum. switch in a n explosive atniospherc.
1
The pentane dehydration tank and the make-up tank are situ- At the first sound of the fire alarm, the plant water pressure is
ated adjacent to each other in an area surrounded by a Transite immediately increbsed by the powerhouse. When the squad
wall. The door to the area is kept closed a t all times, except member assigned to the foam generation unit is notified of a fire
when an operator is inside. The entire area can be flooded with in one of the dike areas, he opens the valve which feeds the dike
live steam in event of a fire. The shed around the c o a l - h d pipe in t h a t area and dumps into the mixing chamber a 5-gallon can of
still can also be flooded with steam in an emergency. Valves on foam generating chemical. Several dikes in the adjacent areas
the steam lines to these zones are located away from potential fire are also flooded with foam. The entire dike system is outlined
areas. in colors on the wall of the fire control house with each dike area
Wherever necessary, all vents carrying flammable vapors are painted a different color and the valve which feeds that dike area
run to the outside of the buildings and are protected with flame painted the same color.
arrestors. It is important in the Venturi mixing chamber, where pentane
All motdrs and other electrical equipment are of explosion- and chlorine are combined under pressure, t h a t the pressures of
proof design when installed in any area where flammable vapors the two components are maintained in the proper relationship.
might be encountered. T o prevent. the entrance of chlorine into the pentane system, an
The two-story buildiiig housing the digesters and the alcohol indicator light device is attached to the pentane feed chamber.
rectification units is equipped with one indoor and three. outdoor When the pressure is maintained at the proper level a green light
slide poles for rapid exit. I n addition, the second floor is con- burns, an excessive pressure rise lights an amber light, And a red
nected by a walkway to an adjacent building. light indicates a drop in the pentane pressure.
A specially engineered 'fie alarm system (6A) is installed Respirators with cartridges for chlorine or hydrogen chloride
throughout the plant with boxes located a t strategic points. vapors are provided .at convenient points. Operators are re-
Employees are instructed to turn in as an alarm any emergency quired to wear a respirator when changing chlorine supply cars,
which could lead to a fire. and gas masks with chlorine canisters are available in case of any
Each storage tank for holding pentane received by tank car is major leaks.
surrounded by a dike about 3 feet high. A fire fighting system, I n the derivatives processes, phenol, caustic, acetic and sulfuric
controlled at a central station, is piped t o each of these dikes. acids, as well as the various amyl compounds must be handled
In the control house there is a mixing chamber which is con- safely. Rubber gloves and goggles are required attire when oper-,
nected with a feed line from the plant water system; foam gener- ators are exposed to any of these skin-corrosive chemicals.
ating chemicals are available and can be added to the water a t
CONTROL
this point.
Operators who would be able to leave their production units in Two separate control groups are maintained a t the Wyandotte
an emergency are designated as members of the plant fire squad; plant. The regular control laboratory checks all raw materials
squad members participate in special training drills. as well as some of the materials in process and finished products.
'I'
WATER
AMYLENE
AMYL CHLORIDE
AMYL MERCAPTAN
SERIES
w
The shipping control group checks all materials prior to shipping. by specific gravity measurement each time one is full. If the
Although much of the routine process control testing is done by specifications are not, met, the product is returned to the column.
the plant operators, there are analysts in the laboratory for each At other points in the process a statistical study of the neces-
shift. sary sampIing frequency has been made. I n several cases i t was
Raw Materials. The boiling range is checked on samples from found that many more samples were being taken than were
each car of mixed pentanes received. Initial boiling point mu'st actually necessary to keep the operation running within the con-
not be below 27' C. and 95% of the sample must boil in the range trol limits.
of 28" to 39' C.; final boiling point must not be above 40' C. Customer Complaints. All complaints from customers are
Infrared absorption analyses are made on every car for company reported to the control group by any employee who receives or
reference and for billing purposes. hears of them. Investigation is made immediately to assign
causes and make corrections. Record cards are kept on each
product showing complaints per lo00 shipments. By means of
control charts whose limits have been determined by statistical
UPPER SPECIFICATION L I M I T : * I I I *C.
study, the quality of the production and shipping techniques can
rHwxssmC: EVuri'miwr
TABLE
VIII. HAW hIATERIAL ~tEQUrREMEsTs
!Fur 10.000 wunds of nroduot) (1Aj Uow Clieniieui Co., Midland, hlich.. heat traaafer inedium,
Donthorn,.
(ZAj Fairbanks. Morse R; C u . , Chiexgo. Ill., reilroad track ecalou.
(3A) Fisher Goveinor <'<>.,hlaralridltown. Iowa. liquid-level contiel-
lers and traps.
(4A) Foxhro &., Y,,x'boro, Mass.. liguid-feed controllera.
(SA) (:anicwcll C"., Newton 1:pper Palls. Muss.. fire alarm aystpnis.
(IiA) Hnvey Corp., IVcst Newwk, Del., wid-resistant chemicd
eqiiipn*ont..
(i.4) Iron I,.iiemsn Mfg. Co.. I'mtland, Ore., w t o m a t i c coal
burlrels.
( S A ) I'fnudler Go.. Koohenter. N. Y., glass-lined equipnrcnt.
(9.4) Thcrmnl Syndioato. Ltd.. Now Yoik.'N. Y., Bull., 4. Vitvcoail
pas absorber..
(10.2) \Vallaoe and Tierrwi, Newark. N. J.. high-cawaoity chlorine
flowmeter.