C4 BASED PROCESS

5.1 BUTADIENE

SYNTHESIS OF BUTADIENE

REACTION MECHANISM

EXTRACTION FROM C4 HYDROCARBONS

DEHYDROGENATION OF N-BUTANE

FROM ETHANOL

FROM BUTENES

FOR LAB USE

FROM ETHANOL

CATALYST : Magnesia-silica

REACTION MECHANISM
i.
Ethanol dehydrogenated to form
acetaldehyde
ii. Condensation of acetaldehyde to form
acetaldol
iii. Dehydrogenation of acetaldol formed
croton aldehyde
iv. Hydrogen transfer reaction with croton
aldehyde added with ethanol

FROM N-BUTANE

REACTION
MECHANISM

Oxidative Dehydrogenation (ODH) of nbutane

PRODUCT
Butadiene
1-butene , trans-2-butene , cis-2-butene
CATALYST
Vanadium-magnesium-oxide (V-Mg-O) @
magnesium vanadate

Magnesia-zirconia(MgO- ) + magnesium
vanadate nano-catalyst

EXTRACTION FROM C4
HYDROCARBONS

REACTION MECHANISM
i.
Crude C4 & DMF solvent input to the 1 st
distillation column
ii. The stream separated into 2
a) C4 raffinate-1
b) Butadiene & acetylene in DMF solvent
iii. The stream with DMF solvent fed to the 2 nd
extractive distillation column, at the same time
the vinylacetylene removed
iv. From the top stream of the column, butadiene
purification will occur and the remain acetylene
removed.
v.
1,3-Butadiene produced in two distillation column

BUTADIENE PRODUCTS

COPOLYMERS FROM BUTADIENE

Styrene Butadiene (SBR)

Acrylonitrile Butadiene (NBR)
Acrylonitrile Butadiene Styrene (ABS)

STYRENE BUTADIENE (SBR)

Styrene(25%) mix with butadiene(75%) and purified by

20% aqueous caustic purification

Then, the stream will continuously passed through 612 glass-line/stainless steel reactors.
Residence time: 5-15 hours
Steam heating, water cooling, refrigeration process
occurs in the reactors
Cold SBR - 5C, 1 atm gauge
Hot SBR - 50C, 3-4 atm gauge
Stripped with chemical inhibitors, next, latex resulting
from the reactors collected in blow down tanks

The latex will fed to the falling film stripper to

remove the unreacted butadiene, and the bottom
fed to perforated plate column to strip out the
styrene

Free emulsion added in the blend tanks and the

latex coagulated to rubber

The crumbs of rubber will float onto shaker

screens, next, catalyst, emulsifiers and other
soluble removed by action of wash water

The crumbs dried in continuous belt dryers with

hot air and pressed into bales

ACRYLONITRILE BUTADIENE (NBR)

Emulsifier(soap), 2-propenenitrile, butadiene monomers and

catalyst fed to the polymerization vessel

Water added into the mixture as the reaction medium

Hot NBR - 30-40C
Cold NBR - 5-15C
Residence time: 5-15 hours

After 70% of conversion, short stop agent will be supply

Dimethyl dithiocarbamate
Diethyl hydroxylamine

Resultant later, the unreacted monomers remove through

steam into slurry stripper

Latex sent through series of filters to remove

unwanted solid

Then, sent to blending tanks to stabilized it with

antioxidant

The yielded polymer latex coagulated using calcium

nitrate, aluminium sulfate and other agent in
aluminium tank

Coagulated substance washed and dried into crumb

rubber

Most polymerization
used

ACRYLONITRILE BUTADIENE
STYRENE(ABS)
Emulsion process
Suspension
Continuous mass

Hybrid emulsion mass process

It combines the features of the emulsion
process, which forms polybutadiene latex and
grafts styrene and acrylonitrile, while, the
mass process, makes the styrene acrylonitrile
component.

1st phase
Rubbery phase dispersed in a continuous glassy
matrix of styrene acrylonitrile copolymer(SAN)
through boundary layer of SAN graft
SAN : rubber polymerized from butadiene

2nd phase
Styrene and acrylonitrile graft-polymerized to the
rubber
Thus, forming the boundary layer between the
dispersed rubber phase and continuous glassy matrix