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AssigneeThe Dow Chemical Company
InventorsDavid L. Trent, George J. Quarderer, Kim G. Bargeron, Douglas C. Greminger, David J. Koranek, Erik J. Stewart, Curtis N. Swisher, Cheryl A. Tirtowidjojo, Danil Tirtowidjojo
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A process of preparing alkylene oxides comprises steps of: (1) optionally forming a hypochlorite solution; (2) contacting chlorine with a solution of a hypochlorite below about 60.degree. C., and a pH of less than about 5.5, with sufficient micromixing to achieve a product hypochlorous acid in a yield of at least about 80 percent; (3) separating at least a portion the hypochlorous acid from an aqueous metal chloride solution wherein the solution is sprayed as droplets; (4) distilling the remaining liquid phase; (5) absorbing the hypochlorous acid and dichlorine monoxide in low-chlorides water to produce a low-chlorides aqueous hypochlorous acid solution; (6) contacting the low-chlorides aqueous hypochlorous acid solution with an olefin in a continuous process to form a olefin chlorohydrin; (7) optionally contacting the olefin chlorohydrin with a base to form a alkylene oxide and a salt solution; and (8) optionally separating the alkylene oxide from the salt solution. (9) optionally removing chlorates from the chloride brine by contacting the chlorates with acid to convert the chlorates to chlorine; and (10) optionally recycling the chlorine. The process yields particularly high yields of the alkylene oxide without substantial production of by-products.
A continuous process for preparing an olefin chlorohydrin comprising steps of:
A process for the manufacture of hypochlorous acid comprising a step of contacting chlorine and a solution of a metal hypochlorite having a hypochlorite concentration of at least about 1M at a temperature below about 60.degree. C., and a pH of less than about 5.5, with sufficient micromixing to achieve a product hypochlorous acid in a yield of at least about 80 mole percent based on hypochlorite.
A process for the manufacture of hypochlorous acid comprising a step of separating at least a portion the hypochlorous acid from an aqueous metal chloride solution thereof, wherein the solution is sprayed as droplets having a volume mean diameter of less than about 500 micrometers into a vapor stream such that at least about 30 mole percent of the hypochlorous acid is rapidly desorbed from the liquid into the vapor phase with hypochlorous acid being in the vapor phase as hypochlorous acid and dichlorine monoxide.
A continuous process of preparing an olefin chlorohydrin comprising a step of contacting a low-chlorides aqueous hypochlorous acid solution with an olefin in a continuous stirred tank reactor at a temperature of at least about 60.degree. C., pressure greater than about one atmosphere (101.3 kPa), less than 30 minutes residence time, HOCl feed concentration less than about 7 weight percent, with internal gas recycle and backmix stirring sufficient to maintain the HOCl concentration in the reactor of 0.2 weight percent or less to form a corresponding olefin chlorohydrin.
Dependencies are inferred from the claim text.