High productivity methanol carbonylation catalysis using iridium -: The Cativa™ process for the manufacture of acetic acid

Methanol carbonylation to acetic acid is catalysed with high rates at low water concentrations using an iridium/iodide based catalyst. The catalyst system exhibits high stability allowing a wide range of process conditions and compositions to be accessed without catalyst precipitation. Two distinct classes of promoters have been identified for the reaction: simple iodide complexes of zinc, cadmium, mercury, indium and gallium and carbonyl complexes of tungsten, rhenium, ruthenium and osmium. The promoters exhibit a unique synergy with iodide salts, such as lithium iodide, under low water conditions. A rate maximum exists at commercially attractive low water conditions, and optimisation of the process parameters gives acetic acid with a selectivity in excess of 99% based upon methanol. The levels of liquid by-products formed are a significant improvement over that achieved with the conventional high water rhodium based catalyst system used in the Monsanto process and the quality of the product obtained under low water concentrations is exceptional. The Cativa(TM) process has now been successfully commercialised on three world scale plants. (C) 2000 Elsevier Science B.V. All rights reserved.