PRESSURIZED CRUDE AROMATIC
CARBOXYLIC ACID FEED MIXES
CROSS-REFERENCE TO RELATED APPLICATIONS
[0001] This appiication claims the benefit of priority from U.S. Provisional
Application No. 61/921 ,706, filed December 30, 2013.
TECHNICAL FIELD
[0002] The present teachings relate generally to processes for
manufacturing aromatic carboxylic acids, and in particular, to processes for
preparing crude aromatic carboxylic acids for purification.
BACKGROUND
[0003] Terephthalic acid (TA) and other aromatic carboxylic acids may be
used in the manufacture of polyesters (e.g., via their reaction with ethylene
glycol and/or higher aikylene glycols). Polyesters in turn may be used to
make fibers, films, containers, bottles, other packaging materials, molded
articles, and the like.
[0004] in commercial practice, aromatic carboxylic acids have been
made by liquid phase oxidation of methyl-substituted benzene and
naphthalene feedstocks in an aqueous acetic acid solvent. The positions of
the methyl substituents correspond to the positions of carboxyl groups in the
aromatic carboxylic acid product. Air or other sources of oxygen (e.g.,
typically in a gaseous state) have been used as oxidants in the presence, for
example, of a bromine-promoted catalyst that contains cobalt and
manganese. The oxidation is exothermic and yields aromatic carboxylic acid
together with by-products, including partial or intermediate oxidation products
of the aromatic feedstock, and acetic acid reaction products (e.g., methanol,
methyl acetate, and methyl bromide). Water is also generated as a by¬
product.
[0005] Pure forms of aromatic carboxylic acids are oftentimes desirable
fo the manufacture of polyesters to be used in important applications (e.g.,
fibers and bottles). Impurities in the acids (e.g., by-products generated from
oxidation of aromatic feedstocks and, more generaily, various carbonylsubstituted
aromatic species) are thought to cause and/or correlate with color
formation in polyesters made therefrom, which in turn leads to off-color in
polyester converted products. Aromatic carboxy!ic acids having reduced
levels of impurities may be made by further oxidizing crude products from
liquid phase oxidation as described above at one or more progressively !ower
temperatures and oxygen levels. In addition, partial oxidation products may
be recovered during crystallization and converted into the desired acid
product.
[0006] Pure forms of terephthalic acid and other aromatic carboxylic
acids having reduced amounts of impurities—for example, purified
terephthalic acid (PTA)— have been made by cata!ytically hydrogenating less
pure forms of the acids or so-called medium purity products in solution at
elevated temperature and pressure using a noble metal catalyst. In
commercial practice, liquid phase oxidation of aiky aromatic feed materials to
crude aromatic carboxylic acid, and purification of the crude product, are
oftentimes conducted in continuous integrated processes in which crude
product from the liquid phase oxidation is used as a starting material for the
purification.
[0 0 ] In conventional purification units, crude aromatic carboxylic acid is
typically mixed with water to form a purification reaction mixture prior to its
introduction to the purification reactor. The mixing occurs in a feed mix
vessel that is maintained at ambient pressure in order to allow rerun aromatic
carboxylic from the vessel and to enable use of a screw conveyor feed of
crude aromatic carboxylic from an intermediate silo to the feed mix vessel,
which requires the feed mix vessel to be pressure-equilibrated with the silo
which operates at ambient pressure. When the feed mix vessel is at ambient
pressure, the highest possible temperature of the water in the vessel is about
100°C, the boiling point of water at ambient pressure. The purification
reaction mixture must be pre-heated prior to its introduction into the
purification reactor, which typically runs at 250°C to 300°C. This heating
requlred to raise the temperature of the purification reaction mixture from
0°C or iess to at !east 250°C adds to the variab!e cost of the integrated
process for manufacturing purified aromatic carboxylic acids.
[0008] There continues to be a need to reduce the overall costs of
manufacturing aromatic carboxyiic acids.
A
[0009] The scope of the present invention is defined soieiy by the
appended claims, and is not affected to any degree by the statements within
this summary.
[0010] According to one aspect of the invention, a process for
manufacturing a purified aromatic carboxyiic acid is provided, A purification
reaction mixture comprising a crude aromatic carboxyiic a d and water is pre¬
heated in a pre~heating zone. The purification reaction mixture enters the pre¬
heating zone at a pressure above ambient. The crude aromatic carboxyiic
acid in purification reaction mixture is then purified to form a purified aromatic
carboxyiic acid product.
[0011] According to another aspect of the invention, a process for
manufacturing a purified aromatic carboxyiic acid is provided. A purification
reaction mixture comprising a crude aromatic carboxyiic acid and water is pre¬
heated in a pre-heating zone. The purification reaction mixture enters the pre¬
heating zone at a temperature above 100°C. The crude aromatic carboxyiic
acid in purification reaction mixture is then purified to form a purified aromatic
carboxyiic acid product.
[0012] Other aspects of the invention w ll be apparent to those skilled in
the art in view of the description that foiiows.
BRIEF DESCRIPTION OF THE DRAWINGS
[0013] FIG. 1 shows a process flow diagram for manufacturing purified
forms of aromatic carboxyiic acids n accordance with the present teachings.
[0014] By way of general introduction, a process for manufacturing a
purified aromatic carboxyiic acid in accordance with the present invention
comprises: heating a purification reaction mixture n a pre-heating zone, the
purification reaction mixture comprising a crude aromatic carboxyiic acid and
water, the purification reaction mixture entering the pre-heating zone at a
pressure above ambient; and purifying the crude aromatic carboxyiic acid in
the purification reaction mixture to form a purified aromatic carboxyiic acid
product. In some embodiments, the purification reaction mixture also enters
the pre-heating zone at temperatures above 100 C which would not be
possible if the purification reaction mixture was maintained at atmospheric
pressure prior to being fed into the pre-heating zone. Accordingly, compared
with prior processes, less heat is required to raise the temperature in the pre¬
heating zone to the temperature required by the purification reactor.
[0 in some embodiments, the purification reaction mixture is
introduced into pre-heating zone at a pressure that is greater than about .0
bar(g), in some embodiments greater than about 2.0 bar(g), in some
embodiments greater than about 3.0 bar(g), in some embodiments greater
than about 4.0 bar(g), in some embodiments greater than about 5.0 bar(g),
and in some embodiments greater than about 8.0 bar(gln some embodiments,
the purification reaction mixture is introduced into the pre-heating zone at a
temperature that is greater than about 105 °C. In some embodiments, the
temperature is greater than about 5 °C, in some embodiments greater than
about 1205 °C, in some embodiments greater than about 125 °C, in some
embodiments greater than about 130 °C, in some embodiments greater than
about 140 °C.
[001 b] n some embodiments, the process further comprises forming the
purification reaction mixture n a mixing by a water containing stream with a
slurry comprising crude aromatic carboxyiic acid. In some embodiments, the
mixing zone is maintained at a at a pressure that is greater than about 1.0
bar(g), in some embodiments greater than about 2.0 bar(g), in some
embodiments greater than about 3,0 bar(g), in some embodiments greater
than about 4.0 bar(g) in some embodiments greater than about 5.0 bar(g),
and in some embodiments greater than about 6.0 bar(g). In some
embodiments, the mixing zone is maintained at a temperature that is greater
than about 105 °C. In some embodiments, the temperature is greater than
about 5 °C, in some embodiments greater than about 120 °C, in some
embodiments greater than about 125 °C, in some embodiments greater than
about 130 C, in some embodiments greater than about 140 °C.
[0017] in some embodiments, purifying the purification reaction mixture
comprises contacting an aqueous solution that comprises at least a portion of
the crude aromatic carboxylic acid with hydrogen in the presence of a
catalyst.
[0018] In some embodiments, the process further comprises oxidizing a
substituted aromatic hydrocarbon with gaseous oxygen in a liquid phase
oxidation reaction mixture comprising a monocarboxylic acid solvent, water,
and a catalyst composition. In some embodiments, the purifying comprises
contacting an aqueous solution that comprises at least a portion of the crude
aromatic carboxylic acid with hydrogen in the presence of a catalyst.
[0019] In some embodiments, the process comprises: oxidizing paraxylene
in a reaction zone to form the crude terephthalic acid, wherein the
oxidizing comprises contacting the para-xylene with gaseous oxygen in a
liquid phase oxidation reaction mixture that comprises acetic acid, water, and
a bromine-promoted catalyst composition; crystallizing the crude terephthalic
acid, transferring at least a portion of the crude terephthalic acid to a mixing
zone maintained at a pressure above ambient temperature and mixing the
crude terephthalic acid with a water containing stream to form a purification
reaction mixture, introducing the purification reaction mixture to a pre-heating
zone and heating the purification reaction mixture to at least 250°C, and
purifying the crude terephthalic acid in a hydrogenation reactor by contacting
the purification reaction mixture with hydrogen in the presence of a catalyst.
[0020] Additional features of the above-described processes for
manufacturing purified forms of aromatic carboxylic acid in accordance with
the present teachings will now be described in reference to the drawing
figures.
[0021] FIG. 1 shows a process flow diagram for manufacturing purified
forms of aromatic carboxylic acids in accordance with one embodiment of the
present invention. As a brief introduction, the process 100 includes an
oxidation reactor 110 configured for liquid phase oxidation of feedstock; a
crystallization zone configured for forming crude solid product from the liquid
phase oxidation reaction mixture, and comprising crystallization vesseis 152
and 156; a solid-liquid separation device 190 configured for separating crude
solid product (and oxidation by-products) from liquid, a mixing zone including
a purification reaction mixture make up vessei 20 configured for preparing
mixtures of crude solid product in purification reaction solvent; a pre-heating
zone including a heat exchanger 208 for heating the purification reaction
mixture prior to its introduction into a purification zone, a purification zone
including a purification reactor 21 configured for purifying the crude aromatic
carboxylic acid a crystallization zone including vessei 220 configured for
forming purified solid product from the purification solution; and a solid-liquid
separation device 230 configured for separating purified solid product from
liquid. The integration of processes in FIG. 1 is meant to be purely
representative, and various other integrated, and non-integrated
configurations may likewise be used.
[0022] Liquid and gaseous streams and materials used in the process
represented in FIG. 1 may be directed and transferred through suitable
transfer lines, conduits, and piping constructed, for example, from materials
appropriate for process use and safety. It will be understood that particular
elements may be physically juxtaposed and, where appropriate, may have
flexible regions, rigid regions, or a combination of both. In directing streams
or compounds, intervening apparatuses and/or optional treatments may be
included. By way of example, pumps, valves, manifolds, gas and liquid flow
meters and distributors, sampling and sensing devices, and other equipment
(e.g., for monitoring, controlling, adjusting, and/or diverting pressures, flows
and other operating parameters) may be present.
[0023] Representative aromatic feedstock materials suitable for use in
the oxidation reactor 110 include but are not limited to aromatic compounds
(e.g., hydrocarbons) substituted at one or more positions with at least one
group that is oxidizable to a carboxylic acid group. In some embodiments, the
positions of the substituents correspond to the positions of the carboxylic acid
groups of the aromatic carboxylic acid being prepared. In some
embodiments, the oxidizable substituents include a ky groups (e.g., methyl,
ethyl, and/or isopropyl groups). In other embodiments, the oxidizable
substituents include oxygen-containing groups, such as a hydroxyalky!,
formyi, aldehyde, and/or keto groups. The substituents may be the same or
different. The aromatic portion of feedstock compounds may be a benzene
nucleus or it may be bi~ or polycyclic (e.g., a naphthalene and/or anthracene
nucleus). In some embodiments, the number of oxidizable substituents on the
aromatic portion of the feedstock compound is equal to the number of sites
available on the aromatic portion. In other embodiments, the number of
oxidizable substituents on the aromatic portion of the feedstock is fewer than
ail such sites (e.g., in some embodiments 1 to 4 and, n some embodiments,
2). Representative feed compounds that may be used in accordance with the
present teachings— alone or in combinations— include but are not limited to
toluene; ethylbenzene and other alkyl-substituted benzenes; o-xylene; pxy
e e; xy ene; to a dehydes, toluic acids, a!kyi benzyl alcohols, -formyi-
4~methylbenzene, 1-hydroxymethyi-4~methylbenzene; methylacetophenone;
1,2,4-trimethylbenzene; 1-formyl~2,4~dimethyl~benzene; 1,2,4,5-tetramethyibenzene;
a ky -, formyi-, acy and hydroxylmethyl-substitufed naphthalenes
(e.g., 2,8-dimethyinaphfhaiene, 2,6-diethylnaphthalene, 2,7-
dimethylnaphthaiene, 2,7-diethylnaphthalene, 2~formyl-8-methyinaphthalene,
2~acyl~6~methyinaphthalene, 2-methyl-8-ethyinaphthalene, and the like); and
the like; and partially oxidized derivatives of any of the foregoing; and
combinations thereof. In some embodiments, the substituted aromatic
compound comprises a methyl-, ethyl-, and/or isopropyl-substituted aromatic
hydrocarbon. In some embodiments, the substituted aromatic compound
comprsses an alkyl-substituted benzene, o-xylene, p-xylene, m~xylene, or the
like, or combinations thereof.
[0024] Aromatic carboxyiic acids manufactured in accordance with the
present teachings are not restricted and include but are not limited to monoand
polycarboxylated species having one or more aromatic rings. n some
embodiments, the aromatic carboxylic acids are manufactured by reaction of
gaseous and liquid reactants in a liquid phase system. In some
embodiments, the aromatic carboxylic acid comprises only one aromatic ring.
n other embodiments, the aromatic carboxylic acid comprises a plurality (e.g.,
two or more) aromatic rings that, in some embodiments, are fused (e.g.,
naphthalene, anthracene, etc.) and, in other embodiments, are not. n some
embodiments, the aromatic carboxylic acid comprises only one carboxylic
acid (e.g., -CO 2H) moiety or a salt thereof (e.g., -CO2X, where X is a cationic
species including but not limited to metal cations, ammonium ions, and the
like). In other embodiments, the aromatic carboxylic acid comprises a
plurality (e.g., two or more) of carboxylic acid moieties or salts thereof.
Representative aromatic carboxylic acids include but are not limited to
terephthalic acid, trimesic acid, trimeliitic acid, phthaiic acid, isophthalic acid,
benzoic acid, naphthalene dicarboxylic acids, and the like, and combinations
thereof. n some embodiments, the present teachings are directed to
manufacture of pure forms of terephthalic acid including purified terephthalic
acid (PTA) and so-called medium purity terephthalic acids.
[00251 A representative type of oxidation that may be conducted in the
oxidation reactor 110 is a liquid phase oxidation that comprises contacting
oxygen gas and a feed material comprising an aromatic hydrocarbon having
substituents oxidizable to carboxylic acid groups in a liquid phase reaction
mixture. In some embodiments, the liquid phase reaction mixture comprises a
monocarboxylic acid solvent and water in the presence of a catalyst
composition comprising at least one heavy metal component (e.g., Co, n, V,
Mo, Cr, Fe, Ni, Zi, Ce, Hf, or the like, and combinations thereof) and a
promoter (e.g., halogen compounds, etc.). In some embodiments, the
oxidation is conducted at elevated temperature and pressure effective to
maintain a liquid phase reaction mixture and form a high temperature, highpressure
vapor phase n some embodiments oxidation of the aromatic feed
materia! in the liquid phase oxidation produces aromatic carboxylic acid as
we i as reaction by-products, such as partiai or intermediate oxidation
products of the aromatic feed material and/or solvent by-products. n some
embodiments, the aromatic carboxylic acid comprises terephthaiic acid, and
the oxidizing comprises contacting para-xyiene with gaseous oxygen in a
liquid phase oxidation reaction mixture that comprises acetic acid, water, and
a bromine-promoted catalyst composition. The liquid-phase oxidation and
associated processes may be conducted as a batch process, a continuous
process, or a semi-continuous process. The oxidation may be conducted in
one or more reactors.
[0026] In a representative embodiment, such as may be implemented as
shown in FIG. 1, liquid feed material comprising at least about 99 wt. %
substituted aromatic hydrocarbon, aqueous acetic acid solution (e.g.,
containing about 70 to about 95 wt. % acetic acid), soluble compounds of
cobalt and manganese (e.g., such as their respective acetates) as sources of
catalyst metals, bromine (e.g., hydrogen bromide) as catalyst promoter, and
air may be continuously charged to oxidation reaction vessel 110 through
inlets, such as inlet 112. In some embodiments, vessel 11 is a pressurerated,
continuous-stirred tank reactor.
[0027] In some embodiments, stirring may be provided by rotation of an
agitator 120, the shaft of which is driven by an external power source (not
shown). Impellers mounted on the shaft and located within the liquid body are
configured to provide forces for mixing liquids and dispersing gases within the
liquid body, thereby avoiding settling of solids in the lower regions of the liquid
body.
[0028] n some embodiments, para-xylene is oxidized in reactor 110,
predominantly to terephthaiic acid. By-products that may form in addition to
terephthaiic acid include but are not limited to partial and intermediate
oxidation products (e.g., 4-carboxybenzaldehyde, ,4~hydroxymefhyl benzoic
acid, p-toluic acid, benzoic acid, and the like, and combinations thereof).
Since the oxidation reaction is exothermic, heat generated by the reaction
may cause boiling of the liquid phase reaction mixture and formation of an
overhead vapor phase that comprises vaporized acetic acid, water vapor,
gaseous by-products f om the oxidation reaction, carbon oxides, nitrogen from
the ai charged to the reaction, unreacted oxygen, and the like, and
combinations thereof.
[0029] The overhead vapor may be removed from the reactor through
vent 6 and sent n a stream 111 to high-pressure distillation column 330.
The separation zone is configured to separate water from the solvent
monocarboxylic acid and return a solvent-rich liquid phase to the reactor via
line 331. A water rich gas phase is removed from the separation zone via
line 334 and for further processed, for example, by recovering energy through
an expander, by condensing water from the gas stream for use in the
purification zone or other parts of the process, and by treatment of waste
gases. Reflux is returned to the column 33Q via line 335. The reflux fluid
may include condensed portions of the water rich gas stream 334 or may
include fluid from other sources. Examples of further processing of the
overhead gas stream and sources of reflux fluids are more fully described in
US. Pat os . 5,723,656, 6,137,001 , 7,935,844, 7,935,845, and 8,173,834.
[0030] n some embodiments, liquid effluent comprising solid oxidation
products slurried n the liquid phase reaction mixture is removed from reaction
vessel 110 through slurry outlet 114 and directed in stream 115 to
crystallization vessel 152, and in turn crystallization vessel 156, for recovery
of a solid product.
[0031] In some embodiments, solid crude product may be recovered
from the liquid by crystallization in one or more stages, such as in a single
crystallization vessel or, as shown in FIG. 1, in a series of multiple stirred
crystallization vessels. In some embodiments, the crystallization process
comprises sequential reductions in temperature and pressure from earlier to
later stages to increase product recovery. By way of example, as shown in
F G. 1, crystallization vessels 152 and 15 may be provided in series and in
fluid communication, such that product slurry from vessel 152 may be
iransferred to vessel 156. Cooling in the crystallization vessels may be
accomplished by pressure release. One or more of the crystallization vessels
may be vented, as at vents 1 4 and 158, to remove vapor resulting from
pressure let down and generation of steam from the flashed vapor to a heat
exchange means (not shown).
[0032] As shown in FIG. 1, the crystallization vessel 1S6 is in fluid
communication with a solid-liquid separation device 190. The solid-liquid
separation device 190 is configured to receive a slurry of solid product from
the crystallization vessel 156. In some embodiments, the solid-liquid
separation device 190 is further configured to separate a crude solid product
and by-products from the liquid. In some embodiments, the separation device
190 is a centrifuge, a rotary vacuum filter, a pressure filter, or the like, or a
combination thereof. In some embodiments, the separation device 190
comprises a pressure filter configured for solvent exchange (e.g., by positive
displacement under pressure of mother liquor in a filter cake with wash liquid
comprising water). The oxidation mother liquor resulting from the separation
may exit separation device 0 in stream 191 for transfer to mother liquor
drum 192. A portion of the mother liquor and, in some embodiments, a major
portion of the mother liquor, may be transferred from drum 192 to oxidation
reactor 110. In such a way, monocarboxylic acid solvent, water, catalyst,
and/or oxidation reaction by-products dissolved and/or present as fine solid
particles in the mother liquor may be returned to the liquid phase oxidation
reaction.
[0033] As shown in FIG. 1, the stream 197 comprising heated crude solid
product may be directed to a mixing zone including a reaction mixture make
up vessel 200. The crude solid product in stream 197 may be mixed and
slurried in make up vessel 200 in with a make-up solvent entering vessel 200
through line 202 to form a purification reaction mixture. In some
embodiments, the purification make-up solvent contains water. In some
embodiments, the solvent line 202 connects to a holding vessel (not shown)
for containing make-up solvent. In other embodiments, the solvent
comprises fresh demineralized water fed from a deaerator. In other
embodiments, the solvent is supplied from another part of the integrated
process 100, For example, in one embodiment, the soivent comprises the
condensate obtained from an off-gas separation in column 330 or from vapors
recovered from a crystallization zone Sources of purification make-up
solvent are more fully described, for example, in US. Pat s. 5,723,658,
6,137,001, 7,935,844, 7,935,845, and 8,173,834.
[0034] The mixing zone is configured to operate at a pressure above
ambient. This pressure is maintained in vessel 200 by sealing the inlet lines
197 and 202 with pumps, filters, control valves or rotary valves (not shown)
and outlet line 204 with pump 208. In one embodiment, the pressure sealing
of vessel 200 is accomplished by providing a rotary pressure filter as solidliquid
separation 190. The rotary pressure filter pressurizes the discharged
slurry exiting the device 190 and entering ine 197. Suitable rotary pressure
filters are sold by BHS-Sonthofen and are disclosed for example, in US Pat
Nos. 2,741 ,369, 7,807,080 and US Pat. App. 20050051473. Purification
reaction mixture is prepared in vessel 200 is withdrawn through in e 204 and
transferred to pump 206, which also acts to maintain the pressure in vessel
200. By maintaining the vessel 200 at a pressure above ambient pressure,
the purification make-up soivent 202 can enter the vessel 200 and be
maintained in the vessel 200 at a pressure above ambient, and therefore may
enter and be maintained at a temperature higher than would be possible than
if the vessel were maintained at ambient temperature. For example, water in
the purification make-up solvent could only be added to vessel at a maximum
of 100°C if the vessel were maintained at one atmosphere absolute pressure.
By allowing purification make-up solvent to have a higher pressure and
temperature when entering the vessel 200, the resulting purification reaction
mixture formed in the vessel 200 will have a higher temperature than would
be possible if the vessel 200 were not maintained at pressure.
[ 35] Suitable sources of pressurized purification rnake-up solvent
include demineralized water, steam condensate, condensate from distillation
in the oxidation section, such as overhead condensed from stream 334, and
condensate from purification crystailizers such as 220.
[0036] Purification reaction mixture exiting vessel 200 through line 204
enters a pre-heating zone. The purification reaction mixture is introduced into
the pre-heating zone at a pressure above ambient, which a iows the
purification reaction mixture to be introduced at a higher temperature than
would have been possible if non-pressurized. The pre-heating zone shown in
FIG 1 includes a pump 206 and a heat exchanger 208 Those skilled in the
art will appreciate that although only one heat exchanger is shown i FIG. 1,
the pre-heating zone may include additional heat exchangers configured in
series or parallel. The heat exchanger 208 raises the temperature of the
purification reaction mixture to a temperature required for a purification
reaction as described below. In one embodiment, the temperature is raised to
at least 250°C. In one embodiment, the temperature is raised to about
290°C. Because the purification reaction mixture enters at a higher
temperature than in conventional, non-pressurized systems, the energy
required for heating the purification reaction mixture in the pre-heating zone is
less than would be required for the conventional, non-pressurized systems.
[0037] The heated purification reaction mixture exits the pre-heating zone
and enters the purification zone. The purification zone includes a purification
reactor 21 . In some embodiments, purification in the purification reactor 210
comprises contacting the purification reaction mixture with hydrogen at
elevated temperature and pressure in the presence of a hydrogenatson
catalyst. In some embodiments, the pressure ranges from about 85 to about
95 kg/cm2. In some embodiments, a portion of the purification liquid reaction
mixture may be continuously removed from hydrogenatson reactor 210 in
stream 211 and directed to a crystallization vessel 220 n a downstream
crystallization zone. In crystallization vessel 220, terephthalic acid and
reduced levels of impurities may be crystallized from the reaction mixture
(e.g., by reducing pressure on the liquid). The resulting slurry of purified
terephthalic acid and liquid formed in vessel 220 may be directed to solidliquid
separation device 230 in stream 221. Vapors resulting from pressure
letdown in the crystallization reactor 220 may be condensed by passage to
heat exchangers (not shown) for cooling. The resulting condensate liquid
may be redirected to the process, for example as recycle to purification feed
makeup tank (not shown), through suitable transfer lines not shown) and/or
be directed to waste water treatment (WWT). Purified terephtha!ic acid exits
solid-liquid separation device 230 in the stream 231. In some embodiments,
at least a portion, n some embodiments all or substantially all, of the
purification mother liquor may be directed in stream 233 as reflux to highpressure
distillation column 330, as more fully described, for example, in US,
Pat. Nos. 5,723,656, 8,137,001, 7,935,844, 7,935,845, and 8,173,834, In
other embodiments, stream 233 may be directed to a waste water treatment
facility. The solid-liquid separation device 230 may be a centrifuge, a rotary
vacuum filter, a pressure filter, or the like, or a combination thereof.
[0038] The entire contents of each and every patent and non-patent
publication cited herein are hereby incorporated by reference, except that in
the event of any inconsistent disclosure or definition from the present
specification, the disclosure or definition herein shall be deemed to prevail.
[0039] The foregoing detailed description and the accompanying
drawings have been provided by way of explanation and Illustration, and are
not intended to limit the scope of the appended claims. Many variations in the
presently preferred embodiments illustrated herein will be apparent to one of
ordinary skill in the art, and remain within the scope of the appended claims
and their equivalents.
[0040] It is to be understood that the elements and features recited in the
appended claims may be combined in different ways to produce new claims
that likewise fall within the scope of the present invention. Thus, whereas the
dependent claims appended below depend from only a single independent or
dependent claim, it is to be understood that these dependent claims can,
alternatively, be made to depend in the alternative from any preceding claim—
whether independent or dependent—and that such new combinations are to
be understood as forming a part of the present specification.
A S
1. A process for manufacturing a purified aromatic carboxyiic acid
comprising;
heating a purification reaction mixture in a pre-heaiing zone; the
purification reaction mixture comprising a crude aromatic carboxyiic acid and
solvent, the purification reaction mixture entering the pre~heating zone at a
pressure above ambient; and
purifying the crude aromatic carboxyiic acid in the purification reaction
mixture to form a purified aromatic carboxyiic acid product.
2. A process for manufacturing a purified aromatic carboxyiic acid
comprising:
heating a purification reaction mixture in a pre-heating zone; the
purification reaction mixture comprising a crude aromatic carboxyiic acid and
solvent, the purification reaction mixture entering the pre~heafing zone at a
temperature above 100°C; and
purifying the crude aromatic carboxyiic acid in the purification reaction
mixture to form a purified aromatic carboxyiic acid product.
3. A process for manufacturing a purified aromatic carboxyiic acid
comprising:
mixing crude aromatic carboxyiic acid and a solvent in a mixing zone
to form purification reaction mixture, the solvent being fed to the mixing zone
at a pressure above ambient;
heating a purification reaction mixture in a pre-heating zone; the
purification reaction mixture comprising a crude aromatic carboxyiic acid and
solvent, the purification reaction mixture entering the pre-heating zone at a
temperature above 1GG°C; and
purifying the crude aromatic carboxyiic acid in the purification reaction
mixture to form a purified aromatic carboxyiic acid product.
4. The process of claim 1 or 2, further comprising:
forming the purification reaction mixture in mixing zone by mixing a
solvent with a stream comprising crude aromatic carboxylic acid.
5. The process of claim 4, wherein the solvent enters the mixing zone at a
pressure above ambient.
6. The process of claim 3 or 5, wherein solvent enters the mixing zone at
a pressure of at least 1 bar(g).
7. The process of claim 3 or 5, wherein the solvent containing stream
enters the mixing zone at a pressure of at least 2 bar(g).
8. The process of claim 3 or 4, wherein the solvent containing stream the
enters mixing zone at temperature above 100°C.
9 The process of claim 3 or 4, wherein the solvent containing stream
enters mixing zone at a temperature of at least 120°C.
10. The process of ciaim 3 or 4, wherein the mixing zone is maintained at a
pressure of at least 2 bar(g).
11. The process of claim 1, 2, or 3, wherein the purification reaction
mixture enters the pre-heating zone at a pressure of at least 80 bar(g).
12. The process of claim 1 or 2, wherein the purification reaction mixture
enters the pre-heating zone at a temperature above 100°C.
13. The process of claim 1, 2, or 3 wherein the purification reaction mixture
enters the pre-heating zone at a temperature of at least 120°C.
14. The process of claim 1. 2, or 3 wherein the aromatic carboxylic acid
comprises terephtha!ic acid.
15. The process of claim 1, 2, or 3 further comprising:
oxidizing a substituted aromatic compound i a reaction zone to form
the crude aromatic carboxylic acid.
transferring effluent from the reaction zone to a crystallization zone;
and
recovering at least a portion of the crude aromatic carboxylic as a solid
from the crystallization zone.
transferring effluent from the crystallization zone to a solid-liquid
separation device, wherein the solid-liquid separation device is configured for
operation above ambient pressure.
16. The process of claim 15 wherein the solid-liquid separation device
comprises a rotary pressure filter.
17. The process of claim 1, 2 or 3 wherein the purification zone comprises
a hydrogenation reactor, and wherein the purifying comprises contacting an
aqueous solution that comprises at least a portion of the crude aromatic
carboxylic acid with hydrogen in the presence of a catalyst.
18. The process of claim 1, 2, or 3 wherein the solvent comprises water.