Petrochemicals & Intermediates

BDO is a low viscosity glycol used almost exclusively as an intermediate to synthetize other chemicals and polymers, such as polyurethanes (PU), polybutylene terephthalate (PBT) and tetrahydrofuran (THF), etc.  

Numerous technologies are commercially used by the market, such as Reppe process (acetylene-based route) and maleic anhydride-based route, etc. 

Maleic anhydride (MAH)-based technology involves several steps. First, di-methyl maleate (DMM) is formed with esterification reaction between MAH and methanol. DMM is hydrogenated to BDO with several hydrogenation steps which is catalyzed by precious metal catalyst or copper catalysts, depends on process set up. BDO is further polished with nickel catalyst to remove the carbonyls. 

Acetylene-based technologies involves following reactions： 

• synthesis of 1,4-butynediol (BYD) via the formaldehyde ethynylation reaction, which is catalyzed by Cu promoted catalyst.   

• Hydrogenation of BYD to BDO with nickel catalyst. 

BASF offers specific catalyst solutions for different technologies with years of commercial reference to fulfill the process and production requirement. Besides that, catalysts are also available for the production of GBL and THF from BDO.

Oxo alcohols can be used in solvent, plasticizer and detergent end products and have carbon chains ranging from 4 to 18 atoms. Normal and branched chains can be hydrogenated over copper or nickel catalyst to obtain the corresponding alcohols. 

Commercial oxo alcohol process involves the following steps, depending on process:

• Hydroformylation to produce oxo aldehyde (addition of synthesis gas to olefins)

• Hydrogenation of oxo aldehyde to oxo alcohol

• Polishing of oxo alcohols 

Aldehyde hydrogenation process can operate in liquid phase or vapor phase while using Cu or Ni catalyst. Ni catalyst is normally used for polishing reactor to remove the carbonyls. BASF has a broad catalyst portfolio to fulfill different production requirement with years of commercial reference and success. Following is a summary of BASF's catalyst offer for commercial oxo alcohol applications. 

BASF offers a suite of precious metal, copper and alumina catalysts that can be used for commercial propylene oxide technology. 

There are currently 5 commercially available process routes for producing propylene oxide.

• The chlorohydrin (CHPO) technology

• The propylene oxide-styrene monomer (POSM) technology

• The propylene-tertiary butyl alcohol (PO/TBA) technology

• The cumene hydroperoxidation (CHPPO) technology 

• The hydrogen peroxide-based propylene oxide (HPPO)

   

BASF offers catalysts with commercial reference to support producers for PO production:

• POSM technology: Cu catalyst for selective hydrogenation of acetophenone to phenylethanol, Al catalyst for dehydration of phenylethanol to styrene

• PO/TBA technology: Pd catalyst for selective hydrogenation of alpha methyl styrene 

• PO/CHPPO technology: Pd catalyst for selective hydrogenation of alpha methyl styrene

• HPPO technology: Pd catalyst for hydrogenation of quinone to hydroquinone, Pd catalyst for selective hydrogenation of peroxides from HPPO waste water 

Removal of aromatic compounds is required for the production of solvents for the chemical industry, paints and drilling fluids. BASF as the technology leader in the solvent dearomatization market offers supported nickel extrudates and precious metal catalysts for this segment. The main products are supported nickel catalysts, Ni 5256 E, Ni 3298 E, Ni 3300 E and Ni 5300 E. These products are offered in the different segments of the market. Which product is offered depends on the boiling range of the solvent/feed and the impurity level. Ni 5300 E and Ni 3300 E are the new development with highest surface area for more severe operating conditions, e.g. high S content. 

Most of the acetone produced worldwide is manufactured from cumene hydroperoxide process as a coproduct with phenol. 

Acetone can be further hydrogenated into IPA, which is a common ingredient in chemicals such as antiseptics, disinfectants and detergents. Commercial acetone hydrogenation application operated in trickle bed phase is normally catalyzed with nickel or copper catalyst. BASF offers commercially proven Cu 0865 T and Ni 3354 E catalyst for achieving >99% conversion of acetone and >99% selectivity of IPA.

Phenol can be further hydrogenated to either cyclohexanol and cyclohexanone.

BASF offers nickel catalyst for production of cyclohexanol. For production of cyclohexanone or mixtures, different Pd/Al catalyst are commercially available by BASF. Enhanced selectivity can be achieved with BASF Pd/Al catalyst.  

Alpha-methylstyrene (AMS) as a byproduct of commercial acetone and phenol production will typically hydrogenated to cumene and recycled. Over 99% conversion of cumene can be achieved with market proven BASF Pd/Al catalysts with 4-7 years operation production. 

Palladium on carbon catalysts are traditionally applied for turning crude terephthalic acid streams into polymer grade terephthalic acid.

BASF offers a broad catalyst portfolio including copper, nickel and precious metal catalyst that can be used for nitroaromatic compound hydrogenation to produce mono-amine or diamine products.

For example, aniline can be produced commercially by the vapor phase hydrogenation of nitrobenzene in both fluidized and fixed bed processes:

BASF's Cu and Nickel catalysts are preferred for high aniline yields without ring saturation. 

BASF also offers commercially proven nickel catalysts that can be used for dinitrotoluene hydrogenation to produce TDA.  

With a broad catalyst portfolio that can be used for reductive amination, BASF can support you to identify the best catalyst to fulfill the production requirement.