PROCESS ECONOMICS PROGRAM

Transcription

1 PROCESS ECONOMICS PROGRAM SRI INTERNATIONAL Mod0 Park, California Abstract Process Economics Program Report No. 1C ISOCYANATES/POLYISOCYANATES In this supplementary report, several processes for manufacture of TDI and PMPPI/MDI are compared; methyl isocyanate production is de- scribed and evaluated; other isocyanates and isocyanate adducts are described. The following are some of the important findings. The carbonylation process for making TDI or PMPPI requires higher capital outlay than the phosgenation process, and also higher production cost, based on prevailing prices of raw material. The situation may change to some extent If cheap carbon monoxide is available. For making PMPPI or MD1 by phosgenation, a clay-catalyzed process based on an Upjohn patent for making the starting amine has some cost advantage over the conventional RCl-catalyzed process and also over other new processes claimed in patents.

2 Report No. 1 C ISOCYANATES PART I SUPPLEMENT C YEN-CHEN YEN 1 I E Cl A private report by the July 1979 PROCESS ECONOMICS PROGRAM Menlo Park, California 94025

3 For detailed marketing data and information, the reader is referred to one of the SRI programs specializing in marketing research. The CHEMICAL ECONOMICS HANDBOOK Program covers most major chemicals and chemical products produced in the United States and the WORLD PETROCHEMICALS Program covers major hydrocarbons and their derivatives on a worldwide basis. In addition, the SRI DIRECTORY OF CHEMICAL PRODUCERS services provide detailed lists of chemical producers by company, product, and plant for the United States and Western Europe. ii

4 CONTENTS 1 INTRODUCTION SUMMARY... General Aspects Technical Aspects TDI by Phosgenation Process TDI by Carbonylation of Dinitrotoluene via Urethane.. Polymethylene Polyphenylenediisocyanate (PPMI) by HCl Condensation and Phosgenation PMPPI with Polyamide Made by a Clay-Catalyzed Process PMPPI with Polyamine Made by Recycled HCl Catalyst... PMPPI by Carbonylation Process Methylene Diphenylene Diamine (MDA) Made by Recycled HCl Catalyst Based on a Bayer Patent..... MDA Made by Clay-Catalyst Condensation Methylene Diphenylene Diisocyanate (MDI) Methyl Isocyanate INDUSTRY STATUS... Production Capacity and Production... Products TOLUENE DIISOCYANATE BY PHOSCRNATION PROCESS Dinitrotoluene Toluenediamine Review of Processes Phosgenation Recovery of TDI Residue Treatment Purification of TDI Phosgene Annihilation Hydrogen Chloride Manufacture of TDI by Phosgenation of TDA Process Description Process Discussion Cost Estimates Costs of Integrated Production Crude or Undistilled TDI Production Costs Pure 2,4 TDI and 65/35 TDI ix

5 CONTENTS 5 METHYLENEDIPHENYL DIISOCYANATE AND POLYMETHYLENE POLYPHENYLISOCYANATE BY PROSGENATION... Review of Processes... MDAandPMPPA... MDIandPMPPI... Manufacture of PMPPA by HCl Condensation and Neutralization... Process Discussion... Cost Estimates... Manufacture of PMPPA Using Recycled Catalyst Based on an Elprochine Patent... Process Discussion... CostEstimates... Manufacture of PMPPA by Clay-Catalyzed Coudensation Based on an Upjohn Patent... CostEstimates.;.... Manufacture of MDA Using Solvent Extraction and Recycled HCl Based on Bayer Patents... Process Discussion... Cost Estimates... Manufacture of MDA Using Clay-Catalyzed Condensation Based on an Upjohn Patent... Cost Estimates... Manufacture of PMPPI by Phosgenation of PMPPA Using a Low Solvent Batio... Cost Estimates... Manufacture of PMPPI by Phosgenation of PMPPA Using a High Solvent Ratio... Production of PMPPI from Aniline--Integration of PMPPAand PMPPI Production.... Manufacture of MD1 as a By-Product in PMPPI Production... Manufacture of MD1 from MDA... Integration Production of PMPPI... a5 a X

6 ILLUSTRATIONS 4.1 TDI by Phosgenation Process 4.2 Recovery of TDI in Residue Production Units Relating to TDI Block Flow Diagram Integrated Production of TDI and TDA Effect of Operating Level and Plant Capacity on Production Cost Integrated Production of TDI, TDA and Phosgene Effect of Operating Level and Plant Capacity on Production Cost Treatment of Crude TDI 5.1 PMPPA by HCl Condensation and Neutralization 5.2 PMPPA Production Effect of Operating Level and Plant Capacity on Production Cost PMPPA Using a Recycled Catalyst Based on an Elprochine Patent 5.4 PMPPA by Clay-Catalyzed Condensation Process Based on an Upjohn Patent 5.5 MDA by HCl Condensation and Extraction Based on a Bayer Patent 5.6 MDA Production Effect of Operating Level and Plant Capacity on Production Cost MDA by Clay-Catalyzed Condensation Process Based on an Upjohn Patent--Separation Section 5.8 PMPPI by Phosgenation of PMPPA 5.9 PMPPI from Aniline Effect of Operating Level and Plant Capacity on Production Cost Separation of MD1 from PMPPI Xi

7 TABLES TDI Production TDI, Distilled and Undistilled TDI from DNT and Carbon Monoxide PMPPI by Phosgenation PMPPI from Nitrobenzene Cost Features.... MD1 Production Methyl Isocyanate Production Producers of Isocyanates in the United States... Producers of Isocyanates In Countries Other than the United States... Commercial Isocyanates... GradesofTDI... GradesofMDI... Grades of PMPPI... Dinitrotoluene PatentSummary... DINITROTOLUENE FROM TOLUENE. CapitalInvestment Toluenediamine Patent Summary TDA FROM DNT BY TBE DU PONT PROCESS Design Bases and Assumptions Capital Investment Xiii

8 TABLES TM FROM DNT BY TEE DU PONT PROCESS (Continued) Toluene Diisocyanate by Phosgenation Distillation and Recovery of TDI Residues from TDI Distillation Purification of TDI Patent Summary Handling of Gas Containing Phosgene Patent Summary TDI FRCM TDA BY PROSCENATION Design Bases and Assumptions StreamFlows Major Equipment Utilities Summary Capital Investment Cost of TDI Production--Various Versions of Design.. Integrated Production of TDI and TDA Integrated Production of TDI, TDA and Phosgene- Integrated Production of TDI, TDA, DNT and Phosgene Integrated Production of TDI, TDA, DNT and Phosgene, and HCl Electrolysis Undistilled TDI Production Costs xiv

9 TABLES Condensation of Aniline and Formaldehyde to Polyamine by HCl Polyamine Processes Using a Small Amount or No HCl Polyamine Treatment Patent Summary Phosgenation of MDA and PMPPA Recovery and Separation of MD1 and PMPPI Reduction of Hydrolyzable Chlorine Content Patent Summary Stabilization of PMPPI PMPPA BY HCl CONDENSATION AND NEUTRALIZATION Design Bases and Assumptions... StreamFlows... Major Equipment... Utilities Summary... Capital Investment... Production Costs... PMPPA USING RECYCLED ACID CATALYST-BASED ON AN ELPROCHINE PATENT Design Bases and Assumptions... StreamFlows... Major Equipment... Utilities Summary... Capital Investment... Production Costs xv

10 TABLES PMPPA BY CLAY-CATALYZED CONDENSATION--BASED ON AN UPJOHN PATENT 5.20 Design Bases and Assumptions StreamFlows Major Equipment Utilities Summary Capital Investment Production Costs MDA BY HCl CONDENSATION,AND EXTBACTION-BASED ON BAYER PATENTS 5.26 Design Bases and Assumptions StreamFlows Major Equipment Utilities Summary Capital Investment Production Costs MDA BY CLAY-CATALYZED CONDENSATION-BASED ON AN UPJOHN PATENT 5.32 Stream Flows--Separation Section Major Equipment-Separation Section Utilities Summary Capital Investment Production Costs... PMPPI BY PHOSGENATION OF PMPPA USING A LOW SOLVENT BAT Design Bases and Assumptions StreamFlows Major Equipment Utilities Summary xvi

11 TABLES PMPPI BY PHOSGENATION OF PMPPA USING A LOW SOLVENT BAT10 (Continued) 5.41 Capital Investment PMPPI BY PHOSGENATION OF PMPPA USING A HIGH SOLVENT RATIO 5.43 Capital Investment PMPPI from Aniline by HCl Condensation and Neutralization 5.46 PMPPI from Aniline Comparison of Production Costs MD1 AND PMPPI 5.47 Major Equipment Utilities Summary Capital Investment Production Costs e MD1 Production Comparison of Production Costs Integrated Production of PMPPI, PMPPA and Phosgene 5.53 PMPPI from Mononitrobentene XVii