Process for producing acetic acid

Abstract

A production process of acetic acid comprises a step for allowing methanol to react with carbon monoxide; a step for feeding a flasher with the reaction mixture to separate a volatile component (2A) and a low-volatile component (2B); a step for feeding a distillation column with the volatile component (2A), and separating an overhead (3A) containing methyl iodide, acetic acid, methyl acetate, water, acetaldehyde, and hydrogen iodide, and a stream (3B) containing acetic acid to collect acetic acid; and a separation step for feeding an acetaldehyde distillation column with at least part of the overhead (3A) and separating a liquid object to be treated containing the overhead (3A) into a lower boiling point component (4A) containing acetaldehyde and a higher boiling point component (4B); wherein, in the separation step, the liquid object contains methanol and/or dimethyl ether in a concentration of 0.1 to 50% by weight is subjected to distillation.

The invention claimed is: 
     
       1. A process for producing acetic acid, which comprises:
 a reaction step for continuously allowing methanol to react with carbon monoxide in the presence of a catalyst system comprising a metal catalyst, a halide salt, and methyl iodide in a carbonylation reactor,   a flash evaporation step for continuously feeding a flasher with a reaction mixture from the reactor to separate a volatile component (2A) containing product acetic acid, methyl acetate, methyl iodide and water, and a low-volatile component (2B) containing the metal catalyst and the halide salt,   an acetic acid collection step for feeding a distillation column with the volatile component (2A), and separating an overhead (3A) containing methyl iodide, acetic acid, methyl acetate, water, by-product acetaldehyde, and hydrogen iodide, and a stream (3B) containing acetic acid to collect acetic acid, and   an acetaldehyde separation step for feeding an acetaldehyde distillation column with at least part of the overhead (3A) and distilling a liquid object to be treated containing the overhead (3A) to separate a lower boiling point component (4A) containing acetaldehyde and a higher boiling point component (4B),   wherein, in the acetaldehyde separation step, the liquid object contains at least one methanol source selected from the group consisting of methanol and dimethyl ether in a concentration of 2 to 50% by weight.   
     
     
       2. A process according to  claim 1 , wherein, in the liquid object, the proportion of methyl iodide is 1 to 98% by weight, the proportion of methyl acetate is 0.5 to 50% by weight, the proportion of acetic acid is 0.2 to 50% by weight, the proportion of water is 0.05 to 95% by weight, and the proportion of hydrogen iodide is 1 to 1000 ppm on the basis of weight. 
     
     
       3. A process according to  claim 1 , wherein the concentration of the methanol source in the liquid object is 2 to 40% by weight. 
     
     
       4. A process according to  claim 1 , wherein the concentration of the methanol source in the liquid object is 2 to 25% by weight. 
     
     
       5. A process according to  claim 1 , wherein, in the liquid object, the concentration of acetic acid is 0.3 to 50% by weight, the ratio of the methanol source (in terms of methanol) is 0.1 to 40 mol relative to 1 mol a total amount of acetic acid and hydrogen iodide. 
     
     
       6. A process according to  claim 1 , wherein the ratio of the methanol source (in terms of methanol) in the liquid object is not less than 80 mol relative to 1 mol of hydrogen iodide. 
     
     
       7. A process according to  claim 1 , wherein, in the liquid object, the concentration of acetic acid is 0.5 to 50% by weight, the concentration of hydrogen odide is 5 to 1000 ppm, and the ratio of the methanol source (in terms of methanol) is 1 to 20 mol relative to 1 mol a a total amount of acetic acid and hydrogen iodide. 
     
     
       8. A process according to  claim 1 , wherein the concentration of the methanol source in the liquid object is adjusted by adding or mixing the methanol source and/or methyl acetate in the following manner (A) and/or manner (B):
 (A) the methanol source and/or methyl acetate is added to or mixed with the overhead (3A) before the overhead (3A) is fed to the acetaldehyde distillation column,   (B) in the acetaldehyde distillation column, the methanol source and/or methyl acetate is added to or mixed with the overhead (3A) at the same height level as a height level at which the overhead (3A) is fed or at a height level upper than the height level at which the overhead (3A) is fed.   
     
     
       9. A process according to  claim 8 , wherein, in the manner (A), a temperature of a mixture containing the overhead (3A) and the methanol source and/or methyl acetate is regulated to 20 to 100° C., and a time from when the overhead (3A) and the methanol source and/or methyl acetate are mixed till when the mixture is fed to the acetaldehyde distillation column is regulated to not less than 5 seconds; and the concentration of the methanol source is adjusted in at least the manner (A). 
     
     
       10. A process according to  claim 8 , wherein, in the manner (A), a temperature of a mixture containing the overhead (3A) and the methanol source and/or methyl acetate is regulated to 30 to 85° C., and a time from when the overhead (3A) and the methanol source and/or methyl acetate are mixed till when the mixture is fed to the acetaldehyde distillation column is regulated to not less than 10 seconds; and the concentration of the methanol source is adjusted in at least the manner (A). 
     
     
       11. A process according to  claim 1 , wherein the material of the acetaldehyde distillation column comprises an iron-based alloy. 
     
     
       12. A process according to  claim 1 , wherein the material of the acetaldehyde distillation column comprises a stainless steel or a two-phase stainless steel. 
     
     
       13. A process for producing acetic acid comprising:
 a reaction step comprising continuously allowing methanol to react with carbon monoxide in the presence of a catalyst system comprising a metal catalyst, a halide salt, and methyl iodide in a carbonylation reactor;   a flash evaporation step comprising continuously feeding a flasher with a reaction mixture from the reactor to separate a volatile component (2A) containing product acetic acid, methyl acetate, methyl iodide and water, and a low-volatile component (2B) containing the metal catalyst and the halide salt;   an acetic acid collection step comprising feeding a distillation column with the volatile component (2A), and separating an overhead (3A) containing methyl iodide, acetic acid, methyl acetate, water, by-product acetaldehyde, and hydrogen iodide, and a stream (3B) containing acetic acid to collect acetic acid; and   an acetaldehyde separation step comprising feeding an acetaldehyde distillation column with at least part of the overhead (3A) and distilling a liquid object to be treated containing the overhead (3A) to separate a lower boiling point component (4A) containing acetaldehyde and a higher boiling point component (4B);   wherein, in the acetaldehyde separation step, the liquid object contains at least one methanol source selected from the group consisting of methanol and dimethyl ether in a concentration of 2 to 50% by weight;   wherein, in the liquid object, the proportion of methyl iodide is 1 to 95% by weight, the proportion of methyl acetate is 0.5 to 50% by weight, the proportion of acetic acid is 0.2 to 50% by weight, the proportion of water is 0.05 to 95% by weight, and the proportion of hydrogen iodide is 1 to 1000 ppm on the basis of weight;   wherein the ratio of the methanol source (in terms of methanol) in the liquid object is not less than 80 mol relative to 1 mol of hydrogen iodide; and   wherein the concentration of the methanol source in the liquid object is adjusted by adding or mixing the methanol source and/or methyl acetate in the following manner (A) and/or manner (B):   (A) the methanol source and/or methyl acetate is added to or mixed with the overhead (3A) before the overhead (3A) is fed to the acetaldehyde distillation column,   (B) in the acetaldehyde distillation column, the methanol source and/or methyl acetate is added to or mixed with the overhead (3A) at the same height level as a height level at which the overhead (3A) is fed or at a height level upper than the height level at which the overhead (3A) is fed.   
     
     
       14. The process according to claim 13, wherein, in the manner (A), a temperature of a mixture containing the overhead (3A) and the methanol source and/or methyl acetate is regulated to 20 to 100° C., and a time from when the overhead (3A) and the methanol source and/or methyl acetate are mixed till when the mixture is fed to the acetaldehyde distillation column is regulated to not less than 5 seconds; and the concentration of the methanol source is adjusted in at least the manner (A). 
     
     
       15. The process according to claim 13, wherein, in the manner (A), a temperature of a mixture containing the overhead (3A) and the methanol source and/or methyl acetate is regulated to 30 to 85° C., and a time from when the overhead (3A) and the methanol source and/or methyl acetate are mixed till when the mixture is fed to the acetaldehyde distillation column is regulated to not less than 10 seconds; and the concentration of the methanol source is adjusted in at least the manner (A).