VINYL ACETATE MONOMER FROM ETHYLENE, ACETIC ACID AND OXYGEN

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Vinyl Acetate Monomer (also known as acetic acid ethenyl ester, acetic acid ethylene ether, acetoxyethene, 1-acetoxyethylene, ethenyl ethanoate, ethenyl acetate, and acetic acid vinyl ester) is a colourless mobile liquid with a pungent odour. It has the formula CH3COOCH=CH2 and is a key raw material in the production of chemicals which are then used to manufacture a wide variety of consumer and industrial products.

The main production method for vinyl acetate monomer is the reaction of ethylene and acetic acid with oxygen, in the presence of a palladium catalyst. The VAM is recovered by condensation and scrubbing and is then purified by distillation. A new manufacturing process, dubbed Leap, could offer large capital cost savings as a more efficient fluidised bed system replaces the fixed bed reactors currently in use.

The oldest means of manufacturing VAM is the addition of acetic acid to acetylene and this process is still used but not on a large scale.

Vinyl acetate monomer is stored in mild steel storage tanks and/or new or reconditioned steel drums and can be transported by bulk vessels or tank trucks. It has a specific gravity of 0.933 and a flash point of -8° C (closed cup) and is highly flammable. It should therefore be stored in a cool, dry, well-ventilated area that is free from the risk of ignition. For transportation purposes, it is classified as packing group II and hazard class 3 and it is an irritant.

Vinyl acetate is a colorless, flammable liquid that also has a characteristic smell that can quickly become irritating. This monomer is used principally in the production of polyvinyl acetate (PVAc) and other vinyl acetate co-polymers. Polyvinyl acetate is a precursor of polyvinilyc alcohol and polyvinyl acetate resins (PVA). Vinyl acetate is also copolymerized as a minor raw material for vinyl chloride and ethylene to form commercial polymers and acrylic fibers.

Vinyl acetate is completely soluble in organic liquids but not in water. At 20ºC a saturated solution of the monomer in water can contain between 2-2.4% of vinyl acetate, while a saturated water solution in vinyl acetate contains 1% of water. At 50ºC the solubility of the monomer in water increases in 0.1% in regards to 20ºC, while the solubility of water in vinyl acetate doubles at 50ºC.

The first available process for the synthesis of vinyl acetate was the acetoxilation of acetylene in gaseous form over a zinc acetate catalyst supported on carbon. This process consisted in the reaction of acetylene with acetic anhydride in a catalyzed medium and high temperature to form dietilene diacetate. This product passed through a cracking tower which in result gave as products acetic acid and vinyl acetate. 2 This type of reaction had a high production percentage (92-98%), but due to the increasing value of acetylene, new technologies and methodologies needed to be research in the 60’s.

The process was modified until acetoxilation in a gaseous phase of ethylene over palladium and gold catalyst supported on silica gel was capable. The catalyst used potassium acetate to help the reaction in a temperature range of 423 ñ 463 K and a pressure range of 600 to 1,000 kPa. This is how ethylene acetoxilation with oxygen, acetic acid and Pd as a catalyst was developed. This process consists of two parts: a process in a homogeneous liquid phase that is used to produce 25% of the production of vinyl acetate, and another heterogeneous gaseous phase process used to produce the last 75% of the product.

The synthesis of vinyl acetate from ethylene, acetic acid and oxygen over a Palladium catalyst is a very important industrial process, but its selectivity is affected by the production of CO2 due to the combustion of the ethylene. Various factors affect the synthesis of vinyl acetate, like for example, the dispersion of Pd, partial pressures from the reactives that are the catalyst additives (near 80% if it is Pd/SiO2 and greater to 94% if it is Pd-Au/SiO2) and contact time. The investigation done by Han, H. F., et al. shows that the ethylene is the principal cause for the production of CO2 due to the fact that combustion kinetic does not change if the acetic acid is taken out of the medium.

The process that involves ethylene, acetic acid, oxygen over a Pd catalyst medium proves to be the best option to develop

Currently, the manufacturing process most widely used to produce vinyl acetate is the vapor phase ethylene process, an oxidative reaction in which ethylene is bubbled through acetic acid at 120°C in the presence of palladium chloride catalyst. Impurities found in the reaction have been reported at less than 1% (for one manufacturer) and have included the following: acetaldehyde, ethyl acetate, and methyl acetate. The vapor phase ethylene process was developed in 1967 to take advantage of ethylene as a cheaper feedstock than acetylene, and came into widespread use in the 1970s. By 1981, the vapor phase ethylene process accounted for 92% of U.S. production and the vapor phase acetylene process accounted for the remainder. Various firms in the United States, Japan, West Germany, and the United Kingdom have independently and/or jointly modified the vapor phase ethylene process by using different types of catalysts in the reaction. The catalyst is usually palladium or its salt, although salts of rhodium, gold, pla
tinum, ruthenium, vanadium, and iridium have also been used. The advantage of these processes is that the catalyst lasts longer and undergoes less corrosion.

A less important commercial manufacturing process for vinyl acetate involves the reaction between acetaldehyde and acetic anhydride. The intermediate species, ethylidene diacetate, undergoes pyrolytic cleavage to vinyl acetate and acetic acid. This process was used in the United States until the 1960s, and may still be in use at small plants in China, India, and Mexico. Vinyl. acetate can also be synthesized in high yields by reacting vinyl chloride with sodium acetate in solution at 50°-75°C, using palladium chloride as a catalyst.

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Description

INTRODUCTION
PROPERTIES
CONTAINERS & REGULATIONS:
HAZARD:
USES AND APPLICATION
USE PATTERN:
VINYL ACETATE MONOMER
TECHNICAL DATA SHEET
GENERAL DESCRIPTION
TYPICAL PROPERTIES (1)
CRITICAL DATA
TYPICAL PROPERTIES (1) (CONTINUED)
GLOBAL MARKET POSITION OF VINYL ACETATE MONOMER
MARKET OPPORTUNITY:
MARKET TENDS
MANUFACTURERS/SUPPLIERS OF VAM
RAW MATERIAL
TECHNOLOGY SOURCES:
SEQUENCES IN VAM PROCESS
ACETIC ACID EVAPORATION COLUMN
REACTOR
NON REACTIVE SUBSTANCE SEPARATOR
ACETIC ACID RECOVERY COLUMN
VAM REFINING COLUMN
PROCESS FLOW DIAGRAM
RAW MATERIAL CALCULATION
REACTION
RAW MATERIALS REQUIRED/MONTHS
VAM PRODUCTION PROCESS
PRODUCTION PROCESS USING ETHYLENE, ACETIC ACID AND OXYGEN
REACTION SYSTEM
THE REACTIONS THAT TAKE PLACE ARE:
VAM DISTILLATION AND DEHYDRATION
PRODUCTION DETAILS OF VINYL ACETATE MONOMER
FIGURE: A SIMPLIFIED PROCESS SCHEME FOR THE PRODUCTION OF VINYL ACETATE MONOMER FROM A FATTY ACID OR TRIACYL
GLYCERIDE-BASED OIL VIA NON-CATALYTIC CRACKING
PROCESS DESCRIPTION OF VAM USING ETHYLENE, ACETIC ACID AND OXYGEN
[MAIN REACTION]
[SIDE REACTION]
TABLE: MATERIALS IN THE VAM PLANT
PROCESS CONSTRAINTS
FIG.: PROCESS FLOW DIAGRAM OF THE VAM PLANT
FIG.: START-UP OPERATION PROCEDURE OF THE VAM PLANT
TECHNICAL ASPECT IN VAM MANUFACTURE
FIGURE: VAM PRODUCTION PROCESS FLOW DIAGRAM.
REACTION SYSTEM
THE REACTIONS THAT TAKE PLACE ARE:
THE RATE LAW FOR THIS REACTION (1) IS GIVEN BY:
VAM DISTILLATION AND DEHYDRATION
UNIT OPERATION IN VAM MANUFACTURE
THE FOLLOWING REACTIONS TAKE PLACE:
FIGURE: VINYL ACETATE MONOMER PROCESS FLOWSHEET
1. CHEMICAL PRODUCT & MANUFACTURER’S DETAILS
2. CHEMICAL IDENTIFICATION
3. HAZARD IDENTIFICATION & HEALTH HAZARD
4. FIRST AID MEASURES
EYE:
SKIN:
INHALATION:
INGESTION:
5. FIRE FIGHTING MEASURES
EXTINGUISHING MEDIA:
SPECIAL FIRE FIGHTING PROCEDURE:
UNUSUAL FIRE AND EXPLOSION HAZARD:
6. ACCIDENTAL RELEASE MEASURES
7. HANDLING AND STORAGE
8. EXPOSURE CONTROLS/PERSONAL PROTECTION
9. PHYSIOCHEMICAL PROPERTIES & FIRE/ EXPLOSION HAZARD DATA
10. STABILITY AND REACTIVITY
11. TOXICOLOGICAL INFORMATION
• ACUTE EFFECTS:
• TARGET ORGANS:
• TOXICITY:
• CARCINOGENICITY:
12. ECOLOGICAL INFORMATION
ECOTOXICITY:
ENVIRONMENTAL FATE: THIS PRODUCT IS READILY BIODEGRADABLE
13. DISPOSAL CONSIDERATION
14. TRANSPORT INFORMATION
15. REGULATORY INFORMATION
EUROPEAN INFORMATION
EC NO: 203-545-4
US INFORMATION
PRINCIPLES OF PLANT LAYOUT
STORAGE LAYOUT:
EQUIPMENT LAYOUT:
SAFETY:
PLANT EXPANSION:
FLOOR SPACE:
UTILITIES SERVICING:
BUILDING:
MATERIAL-HANDLING EQUIPMENT:
RAILROADS AND ROADS:
MAJOR PROVISIONS IN ROAD PLANNING FOR MULTIPURPOSE SERVICE ARE:
PLANT LOCATION FACTORS
PRIMARY FACTORS
1. RAW-MATERIAL SUPPLY:
2. MARKETS:
3. POWER AND FUEL SUPPLY:
4. WATER SUPPLY:
5. CLIMATE:
SPECIFIC FACTORS
6. TRANSPORTATION:
A. AVAILABILITY OF VARIOUS SERVICES AND PROJECTED RATES
7. WASTE DISPOSAL:
8. LABOR:
9. REGULATORY LAWS:
10. TAXES:
11. SITE CHARACTERISTICS:
12. COMMUNITY FACTORS:
13. VULNERABILITY TO WARTIME ATTACK:
14. FLOOD AND FIRE CONTROL:
EXPLANATION OF TERMS USED IN THE PROJECT REPORT
1. DEPRECIATION:
2. FIXED ASSETS:
3. WORKING CAPITAL:
4. BREAK-EVEN POINT:
5. OTHER FIXED EXPENSES:
6. MARGIN MONEY:
7. TOTAL LOAD:
8. LAND AREA/MAN POWER RATIO:
PROJECT IMPLEMENTATION SCHEDULES
INTRODUCTION
PROJECT HANDLING
PROJECT SCHEDULING
PROJECT CONSTRUCTION SCHEDULE
TIME SCHEDULE
LICENCED CHEMICAL TECHNOLOGY AND SERVICES
SUPPLIERS OF PLANT AND MACHINERY
SUPPLIERS OF REACTORS
SUPPLIERS OF CONDENSER
SUPPLIERS OF BOILERS
SUPPLIERS OF STORAGE TANK
SUPPLIERS OF LABORATORY EQUIPMENTS
SUPPLIERS OF HEAT EXCHANGER
SUPPLIERS OF RAW MATERIALS

APPENDIX – A:

01. PLANT ECONOMICS
02. LAND & BUILDING
03. PLANT AND MACHINERY
04. OTHER FIXED ASSESTS
05. FIXED CAPITAL
06. RAW MATERIAL
07. SALARY AND WAGES
08. UTILITIES AND OVERHEADS
09. TOTAL WORKING CAPITAL
10. TOTAL CAPITAL INVESTMENT
11. COST OF PRODUCTION
12. TURN OVER/ANNUM
13. BREAK EVEN POINT
14. RESOURCES FOR FINANCE
15. INSTALMENT PAYABLE IN 5 YEARS
16. DEPRECIATION CHART FOR 5 YEARS
17. PROFIT ANALYSIS FOR 5 YEARS
18. PROJECTED BALANCE SHEET FOR (5 YEARS)

Additional information

Plant Capacity

667 MT/Day

Land & Building

(15 Acres)

Plant & Machinery

US$ 57000000

Rate of Return

62%

Break Even Point

33%