The Geon Company

Oxy Vinyls, LP

Joseph A Cowfer

Victor J Johnston

George H Young

Keith S Kramer

Lawrence Popiel

Oxychlorination catalyst compositions which include a catalytically effective amount of an oxychlorination catalyst and a diluent having certain chemical composition and/or physical properties are disclosed. Processes using such oxychlorination catalyst compositions are also described. Some oxychlorination catalyst compositions and processes disclosed herein can increase the optimal operating temperature, and thereby increase the production capacity of an existing reactor, such as a fluid-bed reactor, compared to other oxychlorination catalyst compositions.

Catalyst compositions and process for oxychlorination

An improved process is disclosed for manufacturing chlorinated hydrocarbon by way of oxychlorination which yields reduced levels of environmental toxins such as, chlorobenzenes, polychlorinated biphenyls, polychlorinated dibenzodioxins and polychlorinated dibenzofurans. The process involves fixed bed or fluid bed catalyzed oxychlorination of a hydrocarbon reactant containing from 1 to 3 carbon atoms. The oxychlorination process consists of contacting the hydrocarbon reactant with oxygen or oxygenated gas and at least a portion of externally obtained hydrogen chloride in the presence of the oxychlorination catalyst in a heated reaction zone operated at from 150&deg; C. to 600&deg; C. and recovering chlorinated hydrocarbon from the effluents of the reaction zone. The improvement consists of the use of at least a portion of the hydrogen chloride from an external source other than from recovery of hydrogen chloride from the thermal pyrolysis of the product from the operated oxychlorination process, wherein the external hydrogen chloride, containing aromatic hydrocarbons, is pretreated before use in the operated oxychlorination process by a means for removal of the aromatic hydrocarbons.

Method for reducing formation of polychlorinated aromatic compounds during oxychlorination of C1-C3 hydrocarbons

An improved process is disclosed for manufacturing chlorinated hydrocarbon by way of a once-through air-based oxychlorination process which yields reduced levels of environmental toxins such as chlorobenzenes, polychlorinated biphenyls, polychlorinated dibenzodioxins and polychlorinated dibenzofurans. The process involves fixed bed or fluid bed catalyzed oxychlorination of a hydrocarbon reactant containing from 1 to 3 carbon atoms. The oxychlorination process consists of contacting the hydrocarbon reactant with air or oxygen enriched air and hydrogen chloride in the presence of the oxychlorination catalyst in a heated reaction zone operated at from 150.degree. C. to 600.degree. C. and recovering chlorinated hydrocarbon from the effluents of the reaction zone. The improvement consists of the use of air which is pretreated before use in the operated oxychlorination process by a means for removal of the aromatic hydrocarbons.

Method for reducing formation of polychlorinated aromatic compounds

3 In accordance with the present invention there is provided a method for making and using an improved chromium catalyst which is useful in oxidation of combustible materials such as hydrocarbons, chloro-carbons, chlorohydrocarbons, polymers and other combustible materials. The process for the catalytic oxidation of combustible material, comprises: contacting a combustible material in a heated reaction zone in the presence of oxygen and a chromium impregnated catalyst prepared by impregnating a supporting material with a chromium compound and calcining the solid material at a temperature and for a time at least sufficient for the supporting material to reach a temperature of at least 725.degree. C. By the method the catalyst exhibits reduced loss of chromium to the environment.

Chromium catalyst and catalytic oxidation process

The subject invention relates to a process for oxychlorination of ethylene to produce 1,2-dichloroethane. The process comprises contacting a mixture of ethylene, oxygen or oxygen containing gas and hydrogen chloride with a fixed or fluidized catalyst composition in a reaction zone and recovering 1,2-dichloroethane from the effluents of the reaction zone. The invention is embodied in a process for the oxychlorination of ethylene to produce 1,2-dichloroethane by contacting a mixture of ethylene, oxygen containing gas and hydrogen chloride with a catalyst composition in a reaction zone and recovering 1,2-dichloroethane from the effluents of the reaction zone the process comprising introducing ethylene, HCl and oxygen containing gas into said reaction zone in a ratio of 1.8 and 2.2 moles of HCl per mole of ethylene and from 0.5 to 1 mole of oxygen per mole of ethylene, the oxychlorination process taking place at a temperature of from 215.degree. C. to 230.degree. C., ethylene conversion on a weight basis is at 99% or higher and the mixture is contacted with a catalyst including a support which has deposited thereon a combination of metal chloride salts, the combination consisting essentially of from 2 to 8% copper, from 0.2 to 2% potassium and from 0.01 to 0.19% magnesium, all percentages expressed as the metals on a weight percent basis.

Oxychlorination process

The subject invention relates to catalyst compositions for oxychlorination of ethylene to produce 1,2-dichloroethane. The catalysts comprise copper chloride, at least one alkali metal, at least one rare earth metal, and at least one Group IIA metal on a high surface area support for fluid bed applications or on a high or low surface area support for fixed bed applications. The catalyst compositions are prepared by depositing the metals on a support. The use of the catalyst compositions of the invention in the oxychlorination of ethylene to EDC results in high percent ethylene efficiency, high EDC product purity and high percent HCl conversion without exhibiting catalyst stickiness. A process for oxychlorination of ethylene to produce 1,2-dichloroethane is also disclosed. The process relies on contacting a mixture of ethylene, oxygen or oxygen containing gas and hydrogen chloride with a fixed or fluidized catalyst composition in a reaction zone and recovering 1,2-dichloroethane from the effluents of the reaction zone.

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Avon Lake, OH, United States of America

Joseph A Cowfer