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EP1718951A4 - Chemical production processes, chemical production systems, and methods for monitoring and altering reactor conditions - Google Patents

Chemical production processes, chemical production systems, and methods for monitoring and altering reactor conditions

Info

Publication number
EP1718951A4
EP1718951A4 EP04704096A EP04704096A EP1718951A4 EP 1718951 A4 EP1718951 A4 EP 1718951A4 EP 04704096 A EP04704096 A EP 04704096A EP 04704096 A EP04704096 A EP 04704096A EP 1718951 A4 EP1718951 A4 EP 1718951A4
Authority
EP
European Patent Office
Prior art keywords
catalyst
stream
product
density
reactant
Prior art date
Legal status (The legal status is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the status listed.)
Withdrawn
Application number
EP04704096A
Other languages
German (de)
French (fr)
Other versions
EP1718951A1 (en
Inventor
William R Lowery
Shaun E Mckay
Benny D Evers
Vimal Sharma
Current Assignee (The listed assignees may be inaccurate. Google has not performed a legal analysis and makes no representation or warranty as to the accuracy of the list.)
Great Lakes Chemical Corp
Original Assignee
Great Lakes Chemical Corp
Priority date (The priority date is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the date listed.)
Filing date
Publication date
Application filed by Great Lakes Chemical Corp filed Critical Great Lakes Chemical Corp
Publication of EP1718951A1 publication Critical patent/EP1718951A1/en
Publication of EP1718951A4 publication Critical patent/EP1718951A4/en
Withdrawn legal-status Critical Current

Links

Classifications

    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B01—PHYSICAL OR CHEMICAL PROCESSES OR APPARATUS IN GENERAL
    • B01J—CHEMICAL OR PHYSICAL PROCESSES, e.g. CATALYSIS OR COLLOID CHEMISTRY; THEIR RELEVANT APPARATUS
    • B01J19/00—Chemical, physical or physico-chemical processes in general; Their relevant apparatus
    • B01J19/0006—Controlling or regulating processes
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B01—PHYSICAL OR CHEMICAL PROCESSES OR APPARATUS IN GENERAL
    • B01D—SEPARATION
    • B01D17/00—Separation of liquids, not provided for elsewhere, e.g. by thermal diffusion
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B01—PHYSICAL OR CHEMICAL PROCESSES OR APPARATUS IN GENERAL
    • B01D—SEPARATION
    • B01D17/00—Separation of liquids, not provided for elsewhere, e.g. by thermal diffusion
    • B01D17/02—Separation of non-miscible liquids
    • B01D17/0208—Separation of non-miscible liquids by sedimentation
    • B01D17/0214—Separation of non-miscible liquids by sedimentation with removal of one of the phases
    • C—CHEMISTRY; METALLURGY
    • C07—ORGANIC CHEMISTRY
    • C07B—GENERAL METHODS OF ORGANIC CHEMISTRY; APPARATUS THEREFOR
    • C07B39/00—Halogenation
    • C—CHEMISTRY; METALLURGY
    • C07—ORGANIC CHEMISTRY
    • C07C—ACYCLIC OR CARBOCYCLIC COMPOUNDS
    • C07C17/00—Preparation of halogenated hydrocarbons
    • C07C17/093—Preparation of halogenated hydrocarbons by replacement by halogens
    • C07C17/20—Preparation of halogenated hydrocarbons by replacement by halogens of halogen atoms by other halogen atoms
    • C07C17/202—Preparation of halogenated hydrocarbons by replacement by halogens of halogen atoms by other halogen atoms two or more compounds being involved in the reaction
    • C07C17/206—Preparation of halogenated hydrocarbons by replacement by halogens of halogen atoms by other halogen atoms two or more compounds being involved in the reaction the other compound being HX
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B01—PHYSICAL OR CHEMICAL PROCESSES OR APPARATUS IN GENERAL
    • B01D—SEPARATION
    • B01D3/00—Distillation or related exchange processes in which liquids are contacted with gaseous media, e.g. stripping
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B01—PHYSICAL OR CHEMICAL PROCESSES OR APPARATUS IN GENERAL
    • B01J—CHEMICAL OR PHYSICAL PROCESSES, e.g. CATALYSIS OR COLLOID CHEMISTRY; THEIR RELEVANT APPARATUS
    • B01J2208/00—Processes carried out in the presence of solid particles; Reactors therefor
    • B01J2208/00008—Controlling the process
    • B01J2208/00654—Controlling the process by measures relating to the particulate material
    • B01J2208/00707—Fouling
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B01—PHYSICAL OR CHEMICAL PROCESSES OR APPARATUS IN GENERAL
    • B01J—CHEMICAL OR PHYSICAL PROCESSES, e.g. CATALYSIS OR COLLOID CHEMISTRY; THEIR RELEVANT APPARATUS
    • B01J2219/00—Chemical, physical or physico-chemical processes in general; Their relevant apparatus
    • B01J2219/00049—Controlling or regulating processes
    • B01J2219/00171—Controlling or regulating processes controlling the density
    • B01J2219/00173—Physical density
    • Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
    • Y02—TECHNOLOGIES OR APPLICATIONS FOR MITIGATION OR ADAPTATION AGAINST CLIMATE CHANGE
    • Y02P—CLIMATE CHANGE MITIGATION TECHNOLOGIES IN THE PRODUCTION OR PROCESSING OF GOODS
    • Y02P20/00—Technologies relating to chemical industry
    • Y02P20/50—Improvements relating to the production of bulk chemicals
    • Y02P20/582—Recycling of unreacted starting or intermediate materials

Definitions

  • the present invention relates to chemical production processes and systems and to methods for monitoring and altering reactor conditions.
  • Chemical manufacturing processes can include single or multiple reactor units and single or multiple separations units. A continuing goal in chemical processing is to synchronize these units together in a fashion that makes the process efficient.
  • An exemplary configuration of reactors and separation units includes the return of unused or excess reactants to a reactor unit from a separation unit.
  • One of the benefits of this configuration is that excess reactants are not discarded but utilized to efficiently produce products.
  • Configured in this manner a chemical process system may be considered a steady state closed chemical process system. In a closed system such as this, in some instances, reduced product recovery can be indicative of the necessity for the replacement of consumables and/or the alteration of process parameters.
  • a consumable replacement is the replacement of catalyst in a catalytic reactor.
  • a method for monitoring reactor conditions includes monitoring reactant recovery stream density.
  • the reactant recovery stream can be configured to return reactants to a reactor having a catalyst.
  • the method also includes altering the catalyst when the density reaches a predetermined amount.
  • One aspect of the present invention provides a production process that includes providing a chemical production system having at least one reactor unit and at least one separation unit.
  • the reactor unit can have reactor parameters. Excess reactant is recovered from the separation unit as a recovery stream and provided to the reactor unit.
  • the recovery stream density is monitored and the reactor parameters are altered when the density reaches a predetermined amount.
  • a chemical production system includes a reactor unit receiving a reactant recovery stream from a separation unit, with the stream being monitored by a density monitor.
  • a chemical process includes reacting a reactant and a starting material in a reactor unit and producing a product stream that includes the reactant, a product, and a by product.
  • the reacting can occur in the presence of catalyst and can deplete the catalyst.
  • the product stream can be separated into two different streams with one of the two different streams being a recycle stream comprising the reactant and the by-product.
  • the recycle stream can be returned to the reactor unit.
  • the returning can include monitoring the recycle stream density to ascertain when the catalyst depletion has passed a threshold level.
  • the recycle density may be monitored at least periodically.
  • the catalyst can be replenished as the density indicates an increased concentration of the by-product in the recycle stream.
  • a chemical production system 10 includes a reactor unit 12 and a separation unit 14.
  • Reactor unit 12 can include catalytic reactors and can be configured to receive and/or react a reactant 16 and a starting material 18.
  • Reactor unit 12 can have reactor parameters that include, starting material and reactant compositions and feed rates, reactor unit temperature and pressure, as well as catalyst composition.
  • Reactant 16 can include such reactants as halogen exchange reactants.
  • An exemplary halogen exchange reaction is the reaction of the starting material CH 2 CI 2 (dichloromethane, R-30) with the halogen exchange reactant HF.
  • This reaction can produce a halogen exchange product CH 2 F 2 (difluoromethane, R 32) and by-products such as CH 2 CIF (chlorofluoromethane, R-31) and HCI (hydrochloric acid).
  • Catalysts can be used to improve reactions such as halogen exchange reactions.
  • Exemplary catalysts for use in halogen exchange reactions include supported and unsupported chromium containing catalysts.
  • Reactor unit 12 can include a catalyst. The catalyst may become depleted through use during the reaction. The depleted catalyst can be replenished.
  • Replenishing the catalyst in one aspect includes replacing some and/or all of the catalyst and in another aspect reactivating some and/or all of the catalyst and in a further implementation some of the catalyst can be reactivated and some can be replaced.
  • product stream 20 can transfer products from reactor unit 12 to separation unit 14.
  • Product stream 20 can include excess reactant such as the halogen exchange reactant and the starting material as well as the product and/or by-products. Portions of product stream 20 can be removed in separation unit 14.
  • Separation unit 14 can include separation units such as distillation apparatus and/or phase separation units such as liquid-liquid phase separation units.
  • separation unit 14 can separate the product stream that includes CH 2 F 2 and excess HF into two streams, a final product stream 24 and a recovery stream 22.
  • Final product stream 24 can include the product such as CH 2 F 2 .
  • Recovery stream 22 can be recovered from separation unit 14. In one implementation, recovery stream 22 can be recovered from the bottoms of a distillation apparatus separation unit. Recovery stream 22 can include excess reactant, such as HF. Recovery stream 22 may also include by-products such as CH 2 CIF and/or starting material such as CH 2 CI 2 . In the exemplary illustration of the figure, recovery stream 22 is returned to reactor unit 12. As depicted, this can be considered a recycle and recovery stream 22 may be considered a recycle stream.
  • recovery stream 22 can be monitored by monitoring device 26.
  • the present invention provides for monitoring the density of recovery stream 22.
  • returning the recycle stream can include monitoring the recycle stream density to ascertain when the catalyst depletion has passed a threshold.
  • Monitoring device 26 can include a densitometer or density meter.
  • An exemplary densitometer or density meter includes a Micromotion Elite CMF 100 with a Hastelloy sensor available from Micro Motion, Inc., A Division of Emerson Process Management, 7070 Winchester Circle, Boulder, Colorado 80301 , USA.
  • monitoring the density can indicate an increase in the concentration of starting material and/or the by-product in recovery stream 22.
  • the density of recovery stream 22 may be monitored periodically or may be monitored continuously. Only an increase in the concentration of the starting material in an exemplary aspect may be indicated by a change in the density and in one aspect only an increase in the concentration of the by-product may be indicative of change in the density of recovery stream 22.
  • the density may indicate a two-fold increase in the concentration of the by-product and/or a two-fold increase in the concentration of the starting material of recovery stream 22.
  • the density can be used to ascertain when the catalyst depletion has passed a threshold level.
  • the threshold level may be the level at which the catalyst is depleted, the catalyst soon will be depleted, and/or the level may be predetermined.
  • conditions of reactor unit 12 may be altered in response to the density of recovery stream 22.
  • a predetermined density amount of recovery stream 22 can promulgate the alteration of the reactor parameters of reactor unit 12.
  • reactor parameters may be altered.
  • reactant 16 is HF
  • starting material 18 is CH 2 CI 2
  • a recovery stream density of 1.04 g/ml can dictate replenishing the catalyst within reactor unit 12.
  • a recovery stream density of 1.01 g/ml can dictate replenishing the catalyst within reactor unit 12.
  • the catalyst being replenished may include a supported chromium catalyst.
  • the catalyst may be replenished by replacing and/or reactivating catalyst.
  • the catalyst may be reactivated by methods known to persons of ordinary skill in the art. One such method includes heating the catalyst in the presence of a reactant such as HF. Additionally, altering the reactor unit is not limited to replacing or regenerating the catalyst.
  • the present invention also includes altering other reaction parameters such as starting material and reactant compositions and feed rates, as well as reactor unit temperature and pressure.

Landscapes

  • Chemical & Material Sciences (AREA)
  • Organic Chemistry (AREA)
  • Chemical Kinetics & Catalysis (AREA)
  • Physics & Mathematics (AREA)
  • Thermal Sciences (AREA)
  • Physical Or Chemical Processes And Apparatus (AREA)
  • Devices And Processes Conducted In The Presence Of Fluids And Solid Particles (AREA)
  • Organic Low-Molecular-Weight Compounds And Preparation Thereof (AREA)

Abstract

The present invention includes chemical production processes and systems as well as methods for monitoring and altering reactor conditions. A method for monitoring reactor conditions includes monitoring reactant recovery stream density and altering the condition when the density reaches a predetermined amount. A chemical production system is provided that includes a reactor unit receiving a reactant recovery stream from a separation unit where the stream can be monitored by a density monitor. A chemical process is also provided that includes reacting a reactant and a starting material in a reactor unit having reactor parameters and producing a product stream that includes the reactant, a product, and a by-product. A recycle stream comprising the reactant and the by-product can be separated from the product stream and returned to the reactor unit. The recycle stream density can be monitored at least periodically and the reactor parameters altered as the density indicates an increased concentration of the by-product in the recycle stream.

Description

DESCRIPTION CHEMICAL PRODUCTION PROCESSES, CHEMICAL PRODUCTION SYSTEMS, AND METHODS FOR MONITORING AND ALTERING REACTOR CONDITIONS
TECHNICAL FIELD The present invention relates to chemical production processes and systems and to methods for monitoring and altering reactor conditions.
BACKGROUND OF THE INVENTION Chemical manufacturing processes can include single or multiple reactor units and single or multiple separations units. A continuing goal in chemical processing is to synchronize these units together in a fashion that makes the process efficient. An exemplary configuration of reactors and separation units includes the return of unused or excess reactants to a reactor unit from a separation unit. One of the benefits of this configuration is that excess reactants are not discarded but utilized to efficiently produce products. Configured in this manner a chemical process system may be considered a steady state closed chemical process system. In a closed system such as this, in some instances, reduced product recovery can be indicative of the necessity for the replacement of consumables and/or the alteration of process parameters. One example of a consumable replacement is the replacement of catalyst in a catalytic reactor. However, because the system is a closed system, the process may run inefficiently until it is determined that a consumable requires replacement. The present invention provides methods for monitoring reactor catalyst and chemical production processes and systems. While the invention is motivated by addressing the above issues and challenges it is, of course, no way so limited. This invention is only limited by the accompanying claims as literally worded and appropriately interpreted in accordance with equitable doctrines.
SUMMARY OF THE INVENTION The present invention includes chemical production processes and systems and methods for monitoring and altering reactor conditions. In one implementation, a method for monitoring reactor conditions includes monitoring reactant recovery stream density. The reactant recovery stream can be configured to return reactants to a reactor having a catalyst. The method also includes altering the catalyst when the density reaches a predetermined amount. One aspect of the present invention provides a production process that includes providing a chemical production system having at least one reactor unit and at least one separation unit. The reactor unit can have reactor parameters. Excess reactant is recovered from the separation unit as a recovery stream and provided to the reactor unit. The recovery stream density is monitored and the reactor parameters are altered when the density reaches a predetermined amount. In an exemplary implementation, a chemical production system is provided that includes a reactor unit receiving a reactant recovery stream from a separation unit, with the stream being monitored by a density monitor. In one implementation, a chemical process is provided that includes reacting a reactant and a starting material in a reactor unit and producing a product stream that includes the reactant, a product, and a by product. The reacting can occur in the presence of catalyst and can deplete the catalyst. The product stream can be separated into two different streams with one of the two different streams being a recycle stream comprising the reactant and the by-product. The recycle stream can be returned to the reactor unit. The returning can include monitoring the recycle stream density to ascertain when the catalyst depletion has passed a threshold level. The recycle density may be monitored at least periodically. The catalyst can be replenished as the density indicates an increased concentration of the by-product in the recycle stream.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS The present invention includes methods for monitoring and altering reactor conditions and chemical production processes and systems. An exemplary implementation of these methods, processes, and systems, shall be described with reference to the figure. Referring to the figure, a chemical production system 10 includes a reactor unit 12 and a separation unit 14. Reactor unit 12 can include catalytic reactors and can be configured to receive and/or react a reactant 16 and a starting material 18. Reactor unit 12 can have reactor parameters that include, starting material and reactant compositions and feed rates, reactor unit temperature and pressure, as well as catalyst composition. Reactant 16 can include such reactants as halogen exchange reactants. An exemplary halogen exchange reaction is the reaction of the starting material CH2CI2 (dichloromethane, R-30) with the halogen exchange reactant HF. This reaction can produce a halogen exchange product CH2F2 (difluoromethane, R 32) and by-products such as CH2CIF (chlorofluoromethane, R-31) and HCI (hydrochloric acid). Catalysts can be used to improve reactions such as halogen exchange reactions. Exemplary catalysts for use in halogen exchange reactions include supported and unsupported chromium containing catalysts. Reactor unit 12 can include a catalyst. The catalyst may become depleted through use during the reaction. The depleted catalyst can be replenished. Replenishing the catalyst in one aspect includes replacing some and/or all of the catalyst and in another aspect reactivating some and/or all of the catalyst and in a further implementation some of the catalyst can be reactivated and some can be replaced. Referring again to the figure, product stream 20 can transfer products from reactor unit 12 to separation unit 14. Product stream 20 can include excess reactant such as the halogen exchange reactant and the starting material as well as the product and/or by-products. Portions of product stream 20 can be removed in separation unit 14. Separation unit 14 can include separation units such as distillation apparatus and/or phase separation units such as liquid-liquid phase separation units. In an exemplary implementation, separation unit 14 can separate the product stream that includes CH2F2 and excess HF into two streams, a final product stream 24 and a recovery stream 22. Final product stream 24 can include the product such as CH2F2. Recovery stream 22 can be recovered from separation unit 14. In one implementation, recovery stream 22 can be recovered from the bottoms of a distillation apparatus separation unit. Recovery stream 22 can include excess reactant, such as HF. Recovery stream 22 may also include by-products such as CH2CIF and/or starting material such as CH2CI2. In the exemplary illustration of the figure, recovery stream 22 is returned to reactor unit 12. As depicted, this can be considered a recycle and recovery stream 22 may be considered a recycle stream. However, the present invention is not limited to the recycle of excess reactants to a reactor unit. The present invention also includes implementations where excess reactants are recovered from other processes and transferred to reactors of separate processes. Referring again to the figure, recovery stream 22 can be monitored by monitoring device 26. In one embodiment, the present invention provides for monitoring the density of recovery stream 22. In one implementation, returning the recycle stream can include monitoring the recycle stream density to ascertain when the catalyst depletion has passed a threshold. Monitoring device 26 can include a densitometer or density meter. An exemplary densitometer or density meter includes a Micromotion Elite CMF 100 with a Hastelloy sensor available from Micro Motion, Inc., A Division of Emerson Process Management, 7070 Winchester Circle, Boulder, Colorado 80301 , USA. In one implementation monitoring the density can indicate an increase in the concentration of starting material and/or the by-product in recovery stream 22. In an exemplary implementation, the density of recovery stream 22 may be monitored periodically or may be monitored continuously. Only an increase in the concentration of the starting material in an exemplary aspect may be indicated by a change in the density and in one aspect only an increase in the concentration of the by-product may be indicative of change in the density of recovery stream 22. The density may indicate a two-fold increase in the concentration of the by-product and/or a two-fold increase in the concentration of the starting material of recovery stream 22. In an exemplary aspect, the density can be used to ascertain when the catalyst depletion has passed a threshold level. The threshold level may be the level at which the catalyst is depleted, the catalyst soon will be depleted, and/or the level may be predetermined. In accordance with the present invention, conditions of reactor unit 12 may be altered in response to the density of recovery stream 22. In an exemplary aspect, a predetermined density amount of recovery stream 22 can promulgate the alteration of the reactor parameters of reactor unit 12. In an exemplary implementation, where the density of recovery stream 22 indicates a two-fold increase of either both of the starting material and/or by-product, reactor parameters may be altered. In a particular implementation where reactant 16 is HF, starting material 18 is CH2CI2, a recovery stream density of 1.04 g/ml can dictate replenishing the catalyst within reactor unit 12. In another implementation a recovery stream density of 1.01 g/ml can dictate replenishing the catalyst within reactor unit 12. As mentioned above, the catalyst being replenished may include a supported chromium catalyst. The catalyst may be replenished by replacing and/or reactivating catalyst. The catalyst may be reactivated by methods known to persons of ordinary skill in the art. One such method includes heating the catalyst in the presence of a reactant such as HF. Additionally, altering the reactor unit is not limited to replacing or regenerating the catalyst. The present invention also includes altering other reaction parameters such as starting material and reactant compositions and feed rates, as well as reactor unit temperature and pressure.

Claims

What is claimed is:
1. A method for monitoring and altering reactor conditions, comprising: monitoring reactant recovery stream density, the reactant recovery stream configured to return reactants to a reactor having catalyst therein; and altering the reactor conditions when the density reaches a predetermined amount.
2. The method of claim 1 wherein the stream comprises a halogen exchange reactant.
3. The method of claim 2 wherein the halogen exchange reactant is HF.
4. The method of claim 2 wherein the stream further comprises a halogen exchange by-product.
5. The method of claim 4 wherein the halogen exchange reactant comprises HF and the by-product comprises CH2CIF.
6. The method of claim 1 wherein the altering comprises replacing the catalyst.
7. The method of claim 6 wherein the catalyst comprises chromium.
8. The method of claim 7 wherein the altering comprises replacing the catalyst when the density reaches 1.04 g/ml.
9. The method of claim 7 wherein the altering comprises replacing the catalyst when the density reaches 1.01 g/ml.
10. The method of claim 1 wherein the reactor is configured to react CH2CI2 with HF is the presence of a catalyst.
11. The method of claim 10 wherein the stream comprises one or more of HF, CH2CI2, and CH2CIF and the altering comprises replacing the catalyst when the density of the stream reaches 1.04 g/ml.
12. The method of claim 10 wherein the stream comprises one or more of HF, CH2CI2, and CH2CIF and the altering comprises replacing the catalyst when the density of the stream reaches 1.01 g/ml.
13. The method of claim 1 wherein the stream is a recycle stream.
14. A production process comprising: providing a chemical production system having at least one catalytic reactor unit and at least one separation unit; recovering excess reactant from the separation unit as a recovery stream and providing the excess reactant to the reactor unit; monitoring the recovery stream density; and altering the reactor unit conditions when the density reaches a predetermined amount.
15. The process of claim 14 wherein the catalytic reactor unit is configured to react CH2CI2 with HF in the presence of a catalyst, and wherein the separation unit comprises a distillation apparatus.
16. The process of claim 15 wherein the excess reactant is recycled from the distillation apparatus bottom and comprises one or more of HF, CH2CI2, and CH2CIF.
17. The process of claim 16 wherein the altering comprises replacing the catalyst when the density reaches 1.04 g/ml.
18. The process of claim 16 wherein the altering comprises replacing the catalyst when the density reaches 1.01 g/ml.
19. The process of claim 14 wherein the density is monitored with a Hastelloy sensor.
20. A chemical production system comprising a reactor unit receiving a reactant recovery stream from a separation unit, the stream being monitored by a density monitor.
21. The system of claim 20 wherein the reactor unit is configured to react CH2CI2 with HF in the presence of a catalyst and the separation unit comprises a distillation apparatus.
22. The system of 21 wherein the stream originates from the bottom of the distillation apparatus and comprises one or more of HF, CH2CI2, and CH2CIF.
23. The system of claim 22 wherein the monitoring comprises replacing the catalyst when the stream density is greater than 1.04 g/ml.
24. The system of claim 22 wherein the monitoring comprises replacing the catalyst when the stream density is greater than 1.01 g/ml.
25. The system of claim 20 wherein the density meter comprises a Hastelloy sensor.
26. A chemical process comprising: reacting a reactant and a starting material in a reactor unit and producing a product stream comprising the reactant, a product, and a by product, the reacting occurring in the presence of a catalyst and depleting the catalyst; separating the product stream into two different streams, one of the two different streams being a recycle stream comprising the reactant and the by product; returning the recycle stream to the reactor unit, the returning comprising monitoring the recycle stream density to ascertain when the catalyst depletion has passed a threshold level; and replenishing the catalyst as the density indicates an increased concentration of the by-product in the recycle stream.
27. The process of claim 26 wherein the reactant comprises HF, the starting material comprises CH2CI2, the product comprises CH2F2 and the by product comprises CH2CIF.
28. The process of claim 27 wherein the catalyst comprises a supported chromium catalyst.
29. The process of claim 28 wherein the separating comprises distilling the product stream and recovering the recycle stream as a bottom product of the distillation.
30. The process of claim 28 wherein the replenishing comprises replacing the catalyst.
31. The process of claim 28 wherein the replenishing comprises reactivating the catalyst.
32. The process of claim 28 wherein the replenishing comprises reactivating some of the catalyst and replacing some of the catalyst.
33. The process of claim 26 wherein the product stream further comprises the starting material and the recycle stream further comprises the starting material.
34. The process of claim 33 wherein the density indicates an increased concentration of both the starting material and the by-product in the recycle stream.
35. The process of claim 33 wherein the density indicates an increased concentration of the starting material in the recycle stream.
36. The process of claim 33 wherein the density indicates only an increased concentration of the starting material.
37. The process of claim 33 wherein the density indicates only an increased concentration of the by-product.
38. The process of claim 33 wherein the reactant comprises HF, the starting material comprises CH2CI2, the product comprises CH2F2 and the by product comprises CH2CIF.
39. The process of claim 38 wherein the catalyst comprises a supported chromium catalyst.
40. The process of claim 39 wherein the separating comprises distilling the product stream and recovering the recycle stream as a bottom product of the distillation.
41. The process of claim 39 wherein the replenishing comprises replacing the catalyst.
42. The process of claim 39 wherein the replenishing comprises reactivating the catalyst.
43. The process of claim 39 wherein the replenishing comprises reactivating some of the catalyst and replacing some of the catalyst.
44. The process of claim 26 wherein the separating comprises distilling the product stream and recovering the recycle stream as a bottom product of the distillation.
45. The process of claim 26 wherein the monitoring comprises periodically monitoring the recycle stream density.
46. The process of claim 26 wherein the monitoring comprises continuously monitoring the recycle stream density.
47. The process of claim 26 wherein the reacting comprises combining the reactant and the starting material in the presence of a catalyst and the replenishing comprises replacing the catalyst.
48. The process of claim 26 wherein the replenishing comprises replacing the catalyst.
49. The process of claim 26 wherein the replenishing comprises reactivating the catalyst.
50. The process of claim 26 wherein the replenishing comprises reactivating some of the catalyst and replacing some of the catalyst
51. A chemical process comprising: reacting a starting material and a reactant to produce a product stream comprising the reactant, a product, and a by-product, wherein the reacting is performed in a reactor unit having reactor parameters; separating a recycle stream from the product stream, the recycle stream comprising the reactant and a concentration of the by-product; returning the recycle stream to the reactor unit, the returning comprising at least periodically determining the recycle stream density; and altering the reactor parameters as the density indicates an increase of the concentration of the by-product.
52. The process of claim 51 wherein at least one of the reactor parameters includes reactor temperature, and wherein the altering comprises changing the reactor temperature.
53. The process of claim 52 wherein the changing comprises increasing the reactor temperature.
54. The process of claim 51 wherein the reactant comprises HF, the starting material comprises CH2CI2, the product comprises CH2F2 and the by-product comprises CH2CIF.
55. The process of claim 54 wherein the reacting comprises combining the HF and CH2CI2 in the presence of a catalyst and the altering comprises changing the reactor temperature.
56. The process of claim 55 wherein the changing comprises increasing the reactor temperature.
57. The process of claim 55 wherein the altering comprises changing the reactor temperature as the density indicates a two-fold increase in the concentration of the by-product in the recycle stream.
58. The process of claim 54 wherein the product stream further comprises the starting material and the recycle stream further comprises a concentration of the starting material.
59. The process of claim 58 wherein the reacting comprises combining the HF and CH2CI2 in the presence of a catalyst and the altering comprises changing the reactor temperature.
60. The process of claim 58 wherein the density indicates an increased concentration of both the starting material and the by-product in the recycle stream.
61. The process of claim 58 wherein the density indicates a two-fold increased concentration of the starting material in the recycle stream.
62. The process of claim 51 wherein the returning comprises continuously determining the recycle stream density.
63. The process of claim 33 wherein the density indicates a two-fold increased concentration of the by-product.
EP04704096A 2004-01-21 2004-01-21 Chemical production processes, chemical production systems, and methods for monitoring and altering reactor conditions Withdrawn EP1718951A4 (en)

Applications Claiming Priority (1)

Application Number Priority Date Filing Date Title
PCT/US2004/001687 WO2005080942A1 (en) 2004-01-21 2004-01-21 Chemical production processes, chemical production systems, and methods for monitoring and altering reactor conditions

Publications (2)

Publication Number Publication Date
EP1718951A1 EP1718951A1 (en) 2006-11-08
EP1718951A4 true EP1718951A4 (en) 2007-11-14

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EP04704096A Withdrawn EP1718951A4 (en) 2004-01-21 2004-01-21 Chemical production processes, chemical production systems, and methods for monitoring and altering reactor conditions

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EP (1) EP1718951A4 (en)
CN (1) CN1906475A (en)
MX (1) MXPA06008234A (en)
WO (1) WO2005080942A1 (en)

Citations (1)

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