Patent ID: 7414149
Filing Date: 2008-08-19
Classification: B01J,C07C

Abstract:
1. A method of safely operating a chemical reaction process, wherein the process is an oxidation process for producing at least one product selected from group consisting of: (meth)acrolein, (meth)acrylic acid, propylene oxide, ethylene oxide, methyl methacrylate, and maleic anhydride and the process comprises providing one or more raw materials selected from the group consisting of a reactive hydrocarbon, an oxidant and a diluent material, to at least one reaction zone, wherein the one or more raw materials form a reactive mixture having a composition; and reacting the reactive hydrocarbon with the oxidant, in the at least one reaction zone, to form a mixed product comprising at least one reaction product, unreacted raw materials and reaction by-products, wherein the reacting step is selected from the group consisting of: the reaction of propane to produce acrylic acid, the reaction of o-xylene or naphthalene to produce phthalic anhydride, the reaction of indanes to produce anthraquinone, the reaction of propylene to produce acrylic acid, the ammoxidation of propylene to produce acrylonitrile; the ammoxidation of methane to produce hydrogen cyanide; the ammoxidation of propane to produce acrylonitrile, the reaction of isobutene to produce methylmethacrylate, the reaction of MTBE to produce methylmeth-acrylate and the oxidative dehydrogenation (ODH) of hydrocarbons, wherein the chemical reaction process further comprises the step of separating the at least one reaction product from the mixed product in at least one separation apparatus, the method of safely operating the chemical reaction process comprising: (a) detecting the existence of an undesirable condition capable of affecting the chemical reaction process and selected from the group consisting of: flammability of the reaction mixture, high reactor pressure, cessation of downstream emissions abatement, lack of containment of the reaction mixture, a runaway reaction, rapidly increasing catalyst temperature, high catalyst temperature, low catalyst temperature, incorrect reactant to oxidant feed ratio, incorrect oxidant to inert ratio, reactor coolant system not operational, low level of coolant in the reactant coolant system, an incomplete reaction, fire detected, liquid propylene in feed, high pressure in reactor effluent line, associated air compressor not operational, an undesirable condition in the associated downstream process, and any condition affecting the safe operation of the reaction; (b) minimizing the reacting of the reactive hydrocarbon with the oxidant; (c) maintaining a flow of materials through the at least one reaction zone such that at least a portion of the reaction mixture is displaced from the at least one reaction zone, d) conducting the displaced reaction mixture to the at least one separation apparatus; and e) minimizing the escape of displaced reaction mixture from the at least one separation apparatus by providing a condensable inert material to one or more of the at least one reaction zone and condensing the condensable inert material after the condensable inert material exits the at least one reaction zone.