Ethane-Based Catalytic Process for Vinyl Chloride Manufacture

Area of Science:

• Catalysis
• Materials Science
• Chemical Engineering

Background:

• Ethane utilization for polyvinyl chloride (PVC) production is desirable for cost and environmental benefits.
• Existing ethane-based PVC manufacturing routes face challenges in efficiency and stability.

Purpose of the Study:

• To discover a catalyst for selective ethane conversion to 1,2-dichloroethane.
• To evaluate catalyst stability and performance for potential PVC production.

Main Methods:

• Screening of rare earth oxychlorides as catalysts for ethane chlorination.
• Testing catalyst selectivity and long-term stability (>50 hours).
• Supporting europium oxychloride on carriers and evaluating its performance in extrudate form.

Main Results:

• Rare earth oxychlorides demonstrated high selectivity (up to 90%) and stability (>50 hours) in converting ethane to 1,2-dichloroethane.
• Supported europium oxychloride maintained high selectivity (up to 90%) and stability (>40 hours).
• The process offers potential for an order of magnitude increase in vinyl chloride productivity compared to oxychlorination.

Conclusions:

• Rare earth oxychlorides are effective catalysts for direct ethane to 1,2-dichloroethane conversion.
• Catalyst stability and selectivity pave the way for industrial ethane-based PVC production.
• This research significantly advances the implementation of ethane as a feedstock for PVC manufacturing.