Abstract: A superior catalyst for the oxychlorination of C.sub.2 hydrocarbon feeds comprises a mixture of copper chloride and alkali metal chloride, especially potassium chloride, and preferably also magnesium chloride, which mixture is deposited on an alumina support that has been thermally stabilized by integral incorporation therein of a certain class of lanthanide oxide. The use of such thermally stable catalyst in the production of chlorinated hydrocarbons such as trichloroethylene and perchloroethylene by oxychlorination of a C.sub.2 hydrocarbon feed results in particularly good process efficiencies in terms of long on-stream times, relatively low reactor corrosion rates, high HCl conversion, reduced burning, and conveniently flexible selectivity to specifically desired product.

Abstract: The use of hitherto known supported catalysts in chlorination processes and oxychlorination processes leads to high pressure drops and to the formation of hot spot temperatures in the reactor. When honeycomb monolithic catalyst supports provided with a multiplicity of channels open at both ends and parallel to the longitudinal axis are used, both the heat dissipation is improved and the pressure drops across the reactor are lowered drastically. This leads ultimately to an increase in the selectivity of the reaction and to a minimization of the combustion rate.

Abstract: A process is provided for the chlorination of ethane using hydrogen chloride, chlorine or mixtures as the chlorinating agent. The process includes reaction steps operated in tandem in separate zones first comprising the reaction of perchloroethylene with hydrogen chloride and oxygen in the presence of an oxychlorination catalyst to give hexachloroethane and water, and second comprising the vapor phase reaction of hexachloroethane with ethane feedstock to produce chlorinated ethanes, chlorinated ethylenes, and hydrogen chloride.

Abstract: A superior catalyst for the oxychlorination of C.sub.2 hydrocarbon feeds comprises a mixture of copper chloride and alkali metal chloride, for instance, potassium chloride, and preferably also magnesium chloride, which mixture is deposited on an alumina support having a surface area in excess of 20 and less than 100 m.sup.2 /g. The thermal stability of such a catalyst composition can be further improved by incorporating 0.2 to 5 percent silica in the alumina support. The use of such microspheroidal catalyst in the production of perchloroethylene and trichloroethylene by oxychlorination of a C.sub.2 hydrocarbon feed in a fluidized bed reactor results in particularly good process efficiencies in terms of high HCl conversion, and good flexible selectivity to specifically desired product, reduced burning, long on-stream times, and relatively low corrosion rates.

Abstract: Perchloroethylene is oxychlorinated to provide hexachloroethane which is reacted with methane to produce methyl chloride which is hydrolyzed to form methyl alcohol product and hydrogen chloride which is recycled to the oxychlorination step.

Abstract: A process is provided for the production of allyl chloride from three carbon atom hydrocarbons (propane and/or propylene) using hydrogen chloride or hydrogen chloride/chlorine mixtures as the chlorinating agent. The process includes reaction steps operated in tandem in separate zones first comprising the reaction of perchloroethylene with hydrogen chloride and oxygen in the presence of an oxychlorination catalyst to give hexachloroethane and water, second comprising the vapor phase reaction of hexachloroethane with propane/propylene feedstock to produce allyl chloride, perchloroethylene, and hydrogen chloride, and third isolating the products of the second step and repeating the first step using as starting materials the thus isolated perchloroethylene and hydrogen chloride.

Abstract: An alkane is reacted with oxygen and available chlorine in the presence of a solid solution catalyst containing iron cations to yield unsaturated hydrocarbons and chlorinated saturated and unsaturated hydrocarbons. In a preferred embodiment of the process, ethane is reacted with oxygen and available chlorine in the presence of a solid solution catalyst containing iron cations to yield vinyl chloride, ethylene, and other valuable by-products. The conversion of ethane to products approaches 100 percent, vinyl chloride is prepared in up to 40 mole percent yield, and the combined yield of vinyl chloride, ethylene dichloride, ethyl chloride, and ethylene is up to 90 mole percent.

Abstract: The production of undesirable 1,1,2-trichloroethane and unsym-tetrachloroethane during the production of perchloroethylene is eliminated or essentially eliminated by an improved oxychlorination reaction. The oxychlorination reaction is carried out in the presence of a copper chloride-alkali metal chloride catalyst mixture deposited on a microspheroidal activated alumina carrier having an average particle size of between about 40 and about 70 microns and a surface area of at least about 100 m.sup.2 /g with the copper chloride and alkali metal chloride being present on the carrier in a weight ratio of at least about 1.2 to 1. Reaction parameters, including, e.g., time, temperature and pressure, are controlled to produce a reaction product containing perchloroethylene and trichloroethylene, and the reaction product is free from 1,1,2-trichloroethane and unsym-tetrachloroethane.

Abstract: An alkane is reacted with oxygen and available chlorine in the presence of a solid solution catalyst containing iron cations to yield unsaturated hydrocarbons and chlorinated saturated and unsaturated hydrocarbons. In a preferred embodiment of the process, ethane is reacted with oxygen and available chlorine in the presence of a solid solution catalyst containing iron cations to yield vinyl chloride, ethylene, and other valuable by-products. The conversion of ethane to products approaches 100 percent, vinyl chloride is prepared in up to 40 mole percent yield, and the combined yield of vinyl chloride, ethylene dichloride, ethyl chloride, and ethylene is up to 90 mole percent.

Abstract: An oxychlorination catalyst contains a copper compound, magnesium oxide and aluminium oxide, and the copper compound is present as a distinct phase on a support in which at least part of the magnesium oxide is in combined form with alumina.

Abstract: Process and system for cooling a reaction effluent containing volatized catalyst wherein the effluent is contacted with circulating cooled solid catalyst in dilute phase transport contact, with the volatized catalyst being condensed onto the solid catalyst.

Abstract: A process for initiating a fluidized bed process for oxychlorination of methane and/or chlorinated derivatives thereof with hydrogen chloride and air.

Abstract: The present invention relates to a novel process of halogenating aliphatic hydrocarbons which comprises, first non-selectively oxyhalogenating a C.sub.2 -C.sub.6 aliphatic hydrocarbon to a partially halogenated intermediate product having an overall avarage empirical formula in which the atomic ratio of halogen to carbon is greater than 1:1, then vapor phase halogenating said intermediate product to form an end product having an atomic ratio of carbon to hydrogen is at least 2:1; thereby selectively coproducing or consuming hydrogen chloride.

Abstract: An alkane is reacted with oxygen and available chlorine in the presence of a solid solution catalyst containing iron cations to yield unsaturated hydrocarbons and chlorinated saturated and unsaturated hydrocarbons. In a preferred embodiment of the process, ethane is reacted with oxygen and available chlorine in the presence of a solid solution catalyst containing iron cations to yield vinyl chloride, ethylene, and other valuable by-products. The conversion of ethane to products approaches 100 percent, vinyl chloride is prepared in up to 40 mole percent yield, and the combined yield of vinyl chloride, ethylene dichloride, ethyl chloride, and ethylene is up to 90 mole percent.

Abstract: In the production of a chlorinated hydrocarbon, such as chlorinated methanes, a purge stream is recovered from the chlorinated hydrocarbon effluent, which contains inerts and unreacted hydrocarbon. The unreacted methane present in the purge stream is combusted to recover the fuel values thereof; e.g., as a fuel in the waste chlorinated hydrocarbon combustion to recover chlorine values, with the inerts then being purged from the system.

Abstract: In an integrated process for oxychlorination and combustion of chlorinated hydrocarbons, chlorinated hydrocarbon is burned to recover chlorine values essentially as hydrogen chloride. Hydrogen chloride is recovered from the effluent from the combustion by absorption with aqueous hydrogen chloride. Hydrogen chloride recovered by the absorption is subsequently recovered and employed in an oxychlorination reaction. A gas containing hydrogen chloride, water vapor and some oxygen recovered from the oxychlorination is cooled to condense aqueous hydrogen chloride which is employed in the absorption for recovering hydrogen chloride. The remaining gas is employed in the combustion of chlorinated hydrocarbons.

Abstract: In an integrated process for oxychlorination and combustion of chlorinated hydrocarbons, chlorinated hydrocarbons is burned to recover chlorine values essentially as hydrogen chloride. Combustion effluent and off-gas from an oxychlorination reaction are simultaneously treated to recover anhydrous hydrogen chloride for use in the oxychlorination reaction. In accordance with one embodiment, off-gas from the oxychlorination is employed in the combustion, prior to hydrogen chloride recovery in order to utilize any oxygen values therein. The process has particular applicability to an oxychlorination reaction of the type wherein a molten salt containing the higher and lower valent chlorides of a multivalent metal is contacted with hydrogen chloride and oxygen to recover hydrogen chloride by enriching the higher valent metal chloride content of the molten salt.

Abstract: Monohalogenated olefins are selectively prepared in high yields from alkanes having 2 to 4 carbon atoms by the reaction of such hydrocarbons with a hydrogen halide and a source of oxygen at a temperature from about 400.degree. to about 650.degree. C. in contact with a catalyst comprising a copper halide and an alkali metal phosphate, particularly potassium phosphate, deposited on an inorganic support. Typically, vinyl chloride is prepared in one step from ethane.

Abstract: The active life of an oxychlorination copper-containing catalyst is extended by the removal of sulfur-containing compounds from the gases fed to the catalyst reaction zone. A copper-containing oxychlorination catalyst which has been deactivated by the deposition of sulfur compounds thereon is reactivated in situ by operating the catalyst bed in an oxygen-free atmosphere for a sufficient period of time. The reactivation of the catalyst is completed when the conversions of hydrocarbon and chlorinating agent to chlorinated products indicate a high level of catalyst activity, as determined by an analysis of the gaseous effluent leaving the catalyst bed.

Abstract: A reaction effluent containing vaporized salt withdrawn from a reaction zone, such as a molten salt reaction zone, is contacted with solid particles to cool the gas and condense vaporized salt onto the particles. Such contacting may be effected in either a fluidized bed of solids or in a dilute phase transport contact zone. Heat is recovered either by indirect heat transfer in the fluidized bed or by separating the solid particles and introduction thereof into a fluidized bed cooled by indirect heat transfer. Solid salt is attrited from the particles during contacting with the reaction gas and fluidizing gas, with such solid salts being returned to the reaction zone.