Process to produce a post catalyst removal composition

Abstract

A process is provided for producing an enriched carboxylic acid compositions produced by contacting composition comprising a carboxylic acid with an enrichment feed in an enrichment zone to form an enriched carboxylic acid composition. This invention also relates to a process and the resulting compositions for removing catalyst from a carboxylic acid composition to produce a post catalyst removal composition.

Description

BRIEF DESCRIPTION OF THE DRAWING

FIGS. 1A & B illustrate an embodiment of the invention where a dried carboxylic acid composition 280 is produced.

FIG. 2 illustrates various embodiments of the invention wherein multiple liquid displacement zones 40 can be used.

FIG. 3 illustrates an embodiment of the invention wherein a crystallized slurry composition 160 can be produced by multiple different processes.

FIG. 4 illustrates an embodiment of the invention wherein the crude carboxylic acid composition or a slurry composition can be produced by multiple different processes.

FIG. 5 illustrates an embodiment of the invention wherein a post catalyst removal composition 200 is produced from a carboxylic acid composition 214 in a catalyst removal zone 180.

FIG. 6 illustrates an embodiment of the invention wherein both a catalyst removal zone 180 and an enrichment zone 210 are utilized to produce an enriched composition 240 from a cooled carboxylic acid composition 170.

FIG. 7 illustrates an embodiment of the invention wherein an enriched composition 240 is produced from a post catalyst removal composition 200 in an enrichment zone 210.

FIG. 8 illustrates an embodiment of the invention showing multiple enrichment feed 220 points.

FIG. 9 illustrates various embodiments of the invention wherein a carboxylic acid composition 214 and/or a crystallized slurry composition 160 are enriched.

FIG. 10 illustrates various embodiments of the invention wherein a carboxylic acid composition 214 is enriched in an extended enrichment zone 213.

FIG. 11 illustrates various embodiments of the invention wherein the enrichment zone 210 and the catalyst removal zone 180 can be combined into at least one combined catalyst removal/enrichment zone 181 or at least one device that accomplishes both functions.

FIGS. 12, 13, 14 and 15 Illustrates an embodiment of the invention showing multiple enrichment feeds 220 in a given process.

FIG. 16 illustrates an embodiment of the invention wherein an enriched composition 240 is sent directly to an esterification reaction zone 610.

FIG. 17 illustrates an embodiment of the invention wherein a water wet cake composition 246 is sent directly to an esterification reactor zone 610.

FIG. 18 illustrates an embodiment of the invention where an aromatic feedstock 10 is utilized to produce a post catalyst removal composition 200.

FIG. 19 illustrates an embodiment of the invention wherein an aromatic feedstock 10 is utilized to produce an enriched composition 240.

FIGS. 20A & B illustrates an embodiment of the invention wherein the catalyst removal zone 180 is optional, and the enrichment zone 210 is required.

Claims

1. A process comprising subjecting at least one stream selected from the group consisting of a cooled carboxylic acid composition, a crystallized slurry composition, a slurry composition, and a crude carboxylic acid composition; a wash feed; and optionally an enrichment feed to a catalyst removal zone to form a post catalyst removal composition, a catalyst rich liquor and optionally, a depleted enrichment feed; wherein said post catalyst removal composition has a catalyst composition of less than 500 ppm; wherein the residence time of said catalyst removal zone is less than 10 seconds.

2. The process according to claim 1 wherein said cooled carboxylic acid composition is cooled to a temperature ranging from about 5° C to about 195° C.

3. The process according to claim 1 wherein said wash ratio is between about 0.2 to about 6.0.

4. The process according to claim 2 wherein said wash feed is at a temperature ranging from about 20° C. to about 90° C.

5. The process according to claim 1 wherein said enrichment feed comprises at least one compound selected from the group consisting of terephthalic acid, isophthalic acid, phthalic acid, benzene-tricarboxylic acid isomers, benzoic acid, hydroxybenzoic acid isomers, hydroxymethylbenzoic acid isomers, dicarboxybiphenyl isomers, dicarboxystilbene isomers, tricarboxybiphenyl isomers, tricarboxybenzophenone isomers, dicarboxybenzophenone isomers, dicarboxybenzil isomers, form-acet-hydroxybenzoic acid isomers, acet-hydroxymethylbenzoic acid isomers, a-bromo-toluic acid isomers, bromo-benzoic acid, bromo-acetic acid, tolualdehye isomers, benzyl alcohol isomers, methyl benzyl alcohol isomers, and phthaldehyde isomers.

6. A process comprising subjecting a cooled carboxylic acid composition or a crystallized slurry composition, or a slurry composition, or a crude carboxylic acid composition and a wash feed, and optionally, an enrichment feed to a catalyst removal zone to form a post catalyst removal composition, and a catalyst rich liquor; wherein said post catalyst removal composition has a catalyst composition of less than 500 ppm; wherein the residence time of said catalyst removal zone is less than 10 seconds.

7. The process according to claim 6 wherein said cooled carboxylic acid composition is cooled to a temperature ranging from about 5° C. to about 195° C.

8. The process according to claim 6 wherein said wash ratio is between about 0.2 to about 1.0.

9. The process according to claim 6 wherein said enrichment feed comprises at least one compound selected from the group consisting of terephthalic acid, isophthalic acid, phthalic acid, benzene-tricarboxylic acid isomers, benzoic acid, hydroxybenzoic acid isomers, hydroxymethylbenzoic acid isomers, dicarboxybiphenyl isomers, dicarboxystilbene isomers, tricarboxybiphenyl isomers, tricarboxybenzophenone isomers, dicarboxybenzophenone isomers, dicarboxybenzil isomers, form-acet-hydroxybenzoic acid isomers, acet-hydroxymethylbenzoic acid isomers, a-bromo-toluic acid isomers, bromo-benzoic acid, bromo-acetic acid, tolualdehye isomers, benzyl alcohol isomers, methyl benzyl alcohol isomers, and phthaldehyde isomers.

10. The process according to claim 7 wherein said enrichment feed comprises at least one compound selected from the group consisting of terephthalic acid, isophthalic acid, phthalic acid, benzene-tricarboxylic acid isomers, benzoic acid, hydroxybenzoic acid isomers, hydroxymethylbenzoic acid isomers, dicarboxybiphenyl isomers, dicarboxystilbene isomers, tricarboxybiphenyl isomers, tricarboxybenzophenone isomers, dicarboxybenzophenone isomers, dicarboxybenzil isomers, form-acet-hydroxybenzoic acid isomers, acet-hydroxymethylbenzoic acid isomers, a-bromo-toluic acid isomers, bromo-benzoic acid, bromo-acetic acid, tolualdehye isomers, benzyl alcohol isomers, methyl benzyl alcohol isomers, and phthaldehyde isomers.

11. A process comprising: (a) oxidizing an aromatic feedstock in a primary oxidation zone to form a crude carboxylic acid composition;(b) optionally, subjecting said crude carboxylic acid composition to a liquid displacement zone to form a slurry composition;(c) crystallizing said slurry composition or said crude carboxylic acid composition in a crystallization zone to form a crystallized slurry composition;(d) cooling and optionally enriching said crystallized slurry composition in a cooling zone to form a cooled carboxylic acid composition; and(e) subjecting said cooled carboxylic acid composition, a wash feed, and optionally, an enrichment feed to a catalyst removal zone to form a post catalyst removal composition and a catalyst rich liquor; wherein said post catalyst removal composition has a catalyst composition of less than 500 ppm; wherein the residence time of said catalyst removal zone is less than 10 seconds.

12. The process according to claim 11 wherein said primary oxidation zone comprises at least one oxidation reactor operated at a temperature from 110° C. to 200° C.

13. The process according to claim 11 wherein said aromatic feedstock is para-xylene.

14. The process according to claim 11 wherein said aromatic feedstock is meta-xylene.

15. The process according to claim 11 wherein said enrichment feed comprises at least one compound selected from the group consisting of terephthalic acid, isophthalic acid, phthalic acid, benzene-tricarboxylic acid isomers, benzoic acid, hydroxybenzoic acid isomers, hydroxymethylbenzoic acid isomers, dicarboxybiphenyl isomers, dicarboxystilbene isomers, tricarboxybiphenyl isomers, tricarboxybenzophenone isomers, dicarboxybenzophenone isomers, dicarboxybenzil isomers, form-acet-hydroxybenzoic acid isomers, acet-hydroxymethylbenzoic acid isomers, a-bromo-toluic acid isomers, bromo-benzoic acid, bromo-acetic acid, tolualdehye isomers, benzyl alcohol isomers, methyl benzyl alcohol isomers, and phthaldehyde isomers.

16. The process according to claim 13 wherein said crystallization zone comprises at least one crystallizer operated at a temperature of 110° C. to 190° C.

17. The process according to claim 11 wherein said cooled carboxylic acid composition is cooled to a temperature ranging from about 20° C. to about 90° C.

18. The process according to claim 11 wherein said cooled carboxylic acid composition is cooled to a temperature ranging from about 5° C. to about 195° C.

19. The process according to claim 12 wherein said cooled carboxylic acid composition is cooled to a temperature ranging from about 5° C. to about 195° C.

20. The process according to claim 11 wherein said wash feed is at a temperature ranging from about 20° C. to about 90° C.

21. The process according to claim 12 wherein said wash feed is at a temperature ranging from about 20° C. to about 90° C.

22. A process comprising: (a) oxidizing an aromatic feedstock in a primary oxidation zone to form a crude carboxylic acid composition;(b) optionally subjecting said crude carboxylic acid composition to a liquid displacement zone to form a slurry composition;(c) oxidizing said slurry composition or said crude carboxylic acid composition in a staged oxidation zone to form a stage oxidation composition;(d) cooling and optionally enriching said crystallized slurry composition in a cooling zone to form a cooled carboxylic acid composition; and(e) subjecting said cooled carboxylic acid composition, a wash feed, and optionally an enrichment feed to a catalyst removal zone to form a post catalyst removal composition;wherein said post catalyst removal composition has a catalyst composition of less than 500 ppm; wherein the residence time of said catalyst removal zone is less than 10 seconds.

23. The process according to claim 22 wherein said primary oxidation zone comprises at least one oxidation reactor operated at a temperature from 110° C. to 200° C.

24. The process according to claim 22 wherein said aromatic feedstock is para-xylene.

25. The process according to claim 22 wherein said aromatic feedstock is meta-xylene.

26. The process according to claim 22 wherein said staged oxidation zone comprises at least one staged oxidation device operated at a temperature of 190° C. to 280° C.

27. The process according to claim 22 wherein said staged oxidation zone comprises at least one staged oxidation device operated at a temperature of 150° C. to 280° C.

28. The process according to claim 27 wherein said crystallization zone comprises at least one crystallizer operated at a temperature of 110° C. to 190° C.

29. The process according to claim 22 wherein said cooled carboxylic acid composition is cooled to a temperature ranging from about 20° C. to about 90° C.

30. The process according to claim 22 wherein said cooled carboxylic acid composition is cooled to a temperature ranging from about 5° C. to about 195° C.

31. The process according to claim 24 wherein said cooled carboxylic acid composition is cooled to a temperature ranging from about 5° C. to about 195° C.

32. The process according to claim 22 wherein said wash feed is at a temperature ranging from about 20° C. to about 90° C.

33. The process according to claim 22 wherein said wash ratio is between about 0.2 to about 1.0.

34. The process according to claim 23 wherein said wash ratio is between about 0.2 to about 1.0.

35. A process comprising: (a) oxidizing an aromatic feedstock in a primary oxidation zone to form a crude carboxylic acid composition;(b) optionally subjecting said crude carboxylic acid composition to a liquid displacement zone to form a slurry composition;(c) cooling and optionally enriching said crude carboxylic acid composition or said slurry composition to form a cooled carboxylic acid composition; and(d) subjecting said cooled carboxylic acid composition, a wash feed, and optionally an enrichment feed to a catalyst removal zone to form a post catalyst removal composition and a catalyst rich liquor; wherein said post catalyst removal composition has a catalyst composition of less than 500 ppm; wherein the residence time of said catalyst removal zone is less than 10 seconds.

36. The process according to claim 35 wherein said primary oxidation zone comprises at least one oxidation reactor operated at a temperature from 110° C. to 200° C.

37. The process according to claim 35 wherein said aromatic feedstock is para-xylene.

38. The process according to claim 35 wherein said aromatic feedstock is meta-xylene.

39. The process according to claim 35 wherein said crystallization zone comprises at least one crystallizer operated at a temperature of 110° C. to 190° C.

40. The process according to claim 35 wherein said cooled carboxylic acid composition is cooled to a temperature ranging from about 20° C. to about 90° C.

41. The process according to claim 35 wherein said cooled carboxylic acid composition is cooled to a temperature ranging from about 5° C. to about 195° C.

42. The process according to claim 35 wherein said cooled carboxylic acid composition is cooled to a temperature ranging from about 5° C. to about 195° C.

43. The process according to claim 35 wherein said wash feed is at a temperature ranging from about 20° C. to about 90° C.

44. The process according to claim 36 wherein said wash feed is at a temperature ranging from about 20° C. to about 90° C.

45. The process according to claim 35 wherein a liquid displacement zone is between the staged oxidation zone and crystallization zone and/or between the crystallization zone and cooling zone.

46. A process comprising: (a) oxidizing an aromatic feedstock in a primary oxidation zone to form a crude carboxylic acid composition;(b) optionally subjecting said crude carboxylic acid composition to a liquid displacement zone to form a slurry composition;(c) crystallizing said staged oxidation composition in a crystallization zone to form a crystallized slurry composition; and(d) subjecting said crystallized slurry composition, a wash feed, and optionally, an enrichment feed to a catalyst removal zone to form a post catalyst removal composition; wherein said post catalyst removal composition has a catalyst composition of less than 20 ppm; wherein the residence time of said catalyst removal zone is less than 10 seconds.

47. The process according to claim 46 wherein said primary oxidation zone comprises at least one oxidation reactor operated at a temperature from 110° C. to 200° C.

48. The process according to claim 46 wherein said aromatic feedstock is para-xylene.

49. The process according to claim 46 wherein said aromatic feedstock is meta-xylene.

50. The process according to claim 46 wherein said staged oxidation zone comprises at least one staged oxidation device operated at a temperature of 190° C. to 280° C.

51. The process according to claim 47 wherein said staged oxidation zone comprises at least one staged oxidation device operated at a temperature of 190° C. to 280° C.

52. The process according to claim 46 wherein said staged oxidation zone comprises at least one staged oxidation device operated at a temperature of 150° C. to 280° C.

53. The process according to claim 52 wherein said crystallization zone comprises at least one crystallizer operated at a temperature of 110° C. to 190° C.

54. The process according to claim 46 wherein said cooled carboxylic acid composition is cooled to a temperature ranging from about 20° C. to about 90° C.

55. The process according to claim 46 wherein said cooled carboxylic acid composition is cooled to a temperature ranging from about 5° C. to about 195° C.

56. The process according to claim 47 wherein said cooled carboxylic acid composition is cooled to a temperature ranging from about 5° C. to about 195° C.

57. The process according to claim 46 wherein said wash feed is at a temperature ranging from about 20° C. to about 90° C.

58. The process according to claim 46 wherein said wash feed is at a temperature ranging from about 5° C. to about 195° C.

59. The process according to claim 58 wherein a liquid displacement zone is between the staged oxidation zone and crystallization zone and/or between the crystallization zone and cooling zone.

60. A process to produce a enriched composition comprising: (a) oxidizing an aromatic feedstock in a primary oxidation zone to form a crude carboxylic acid composition;(b) optionally subjecting said crude carboxylic acid composition to a liquid displacement zone to form a slurry composition;(c) oxidizing said slurry composition or said crude carboxylic acid composition in a staged oxidation zone to form a stage oxidation composition;(d) subjecting said staged oxidation composition composition, a wash feed, and optionally an enrichment feed to a catalyst removal zone to form a post catalyst removal composition; wherein said post catalyst removal composition has a catalyst composition of less than 20 ppm; wherein the residence time of said catalyst removal zone is less than 10 seconds.

61. The process according to claim 60 wherein said primary oxidation zone comprises at least one oxidation reactor operated at a temperature from 110° C. to 200° C.

62. The process according to claim 61 wherein said aromatic feedstock is para-ylene.

63. The process according to claim 61 wherein said aromatic feedstock is meta-xylene.

64. The process according to claim 60 wherein said staged oxidation zone comprises at least one staged oxidation device operated at a temperature of 190° C. to 280° C.

65. The process according to claim 61 wherein said staged oxidation zone comprises at least one staged oxidation device operated at a temperature of 190° C. to 280° C.

66. The process according to claim 60 wherein said staged oxidation zone comprises at least one staged oxidation device operated at a temperature of 150° C. to 280° C.

67. The process according to claim 66 wherein said crystallization zone comprises at least one crystallizer operated at a temperature of 110° C. to 190° C.

68. The process according to claim 60 wherein said cooled carboxylic acid composition is cooled to a temperature ranging from about 20° C. to about 90° C.

69. The process according to claim 60 wherein said cooled carboxylic acid composition is cooled to a temperature ranging from about 5° C. to about 195° C.

70. The process according to claim 61 wherein said cooled carboxylic acid composition is cooled to a temperature ranging from about 5° C. to about 195° C.

71. The process according to claim 60 wherein said wash feed is at a temperature ranging from about 20° C. to about 90° C.

72. The process according to claims 1, 6, 11, 22, 35, 46, or 60 wherein the residence time of said catalyst removal zone is less than 7 seconds

73. The process according to claims 1, 6, 11, 22, 35, 46, or 60 wherein the residence time of said catalyst removal zone is less than 5 seconds

74. The process according to claims 1, 6, 11, 22, 35, 46, or 60 wherein the residence time of said catalyst removal zone is less than 3 seconds