Energy and environmentally integrated method for production of aromatic dicarboxylic acids by oxidation

1. A continuous process to prepare an aromatic dicarboxylic acid, comprising:

oxidizing a di-alkyl substituted aromatic compound with compressed air in an acetic acid reaction medium in a primary bubble column reactor in the presence of a catalyst to obtain a three phase reaction medium;

removing a portion of the three phase reaction medium containing catalyst from the primary bubble column reactor to a post-oxidation bubble column unit supplied with compressed air to obtain a post oxidized reaction medium;

transferring the post oxidized reaction medium to a de-gassing unit and separating the post oxidation reaction medium to an overhead gas and an underflow slurry;

collecting an overhead gas from each of the primary oxidation reactor and the post-oxidation reactor with the overhead gas from the de-gassing unit and conducting the combined overhead gases to a water removal column (WRC);

transferring the underflow slurry from the de-gassing unit to a digestion unit wherein the temperature of the underflow slurry is increased to a temperature to at least partially dissolve precipitated solids and effect further oxidation of exposed intermediate oxidation products with air and catalyst present in the underflow slurry without addition of air to the digestion unit, to obtain a final oxidation slurry;

removing overhead gases from the digestion unit to the water removal column;

crystallizing the final oxidation slurry to obtain a filtration-ready slurry of the aromatic dicarboxylic acid;

filtering the filtration-ready slurry on a rotary pressure filter to obtain a mother liquor filtrate and a filtercake;

wherein

the overhead gases sent to the water removal column are separated in the water removal column to an off gas comprising steam removed from the top of the column and an underflow liquid comprising acetic acid,

at least a portion of the energy of the off gas comprising steam is collected and employed to drive an air compressor to supply the compressed air to the bubble column primary reactor and the post-oxidation bubble column unit, and

the water content of the continuous oxidation is controlled by removal of water condensed from the water removal column off-gas.

2. The process of claim 1 , further comprising:

passing the off-gas comprising steam from the water removal column through at least one heat exchange steam generator to employ thermal energy of the off-gas to produce process utility steam and a heat exchanged stream;

collecting and removing condensed water from the heat exchanged stream to obtain a pressurized vapor stream; and

sending the pressurized vapor stream to a gas expander to drive the air compressor.

3. The process of claim 2 , wherein the condensed water from the heat exchanged stream is returned to the WRC or optionally removed as waste.

4. The process of claim 1 , further comprising:

superheating the off-gas comprising steam from the water removal column;

passing the superheated off-gas to a gas expander to drive the air compressor; and

passing the expanded stream from the expander to at least one heat exchange steam generator to produce process utility steam and a heat exchanged stream; and

collecting and removing condensed water from the heat exchanged stream.

5. The process of claim 4 , wherein the condensed water from the heat exchanged stream is returned to the WRC or optionally removed as waste.

6. The process of claim 1 , further comprising:

washing the filtercake with acetic acid;

flowing nitrogen gas through the acetic acid washed filtercake to obtain a solid filtercake;

drying the solid filtercake to remove acetic acid;

reslurrying and purifying the dried filtercake of the aromatic dicarboxylic acid in an aqueous medium to obtain a purified dicarboxylic acid slurry;

filtering the purified aqueous slurry in a rotary pressure filter to obtain a final filtercake of the aromatic dicarboxylic acid and an aqueous mother liquor filtrate;

membrane filtering the aqueous mother liquor filtrate to obtain a water permeate; and

transferring the water permeate to the water removal column as water reflux.

7. The process of claim 6 wherein the acetic acid of the filtercake washing comprises acetic acid from the underflow liquid of the WRC.

8. The process of claim 6 , wherein reslurrying and purifying the dried filtercake of the dicarboxylic acid comprises:

reslurrying the dried filtercake of the aromatic dicarboxylic acid in an aqueous medium;

treating the aqueous slurry with hydrogen in the presence of a hydrogenation catalyst to obtain a crystallization ready aromatic dicarboxylic acid slurry;

crystallizing the aromatic dicarboxylic acid in a series of at least two crystallization units;

filtering the crystallized aqueous slurry in a rotary pressure filter to obtain the final filtercake of the aromatic dicarboxylic acid and the aqueous mother liquor filtrate.

9. The process of claim 8 , wherein water of the reslurry aqueous medium is obtained from the condensate of the overhead vapors from the WRC.

10. The process of claim 1 , further comprising:

washing the filtercake with water to remove acetic acid and catalyst;

flowing nitrogen gas through the water washed filtercake to obtain a solid filtercake;

reslurrying and purifying the solid filtercake of the aromatic dicarboxylic acid in an aqueous medium to obtain purified aromatic dicarboxylic acid slurry;

filtering the purified aqueous slurry in a rotary pressure filter to obtain a final filtercake of the aromatic dicarboxylic acid and an aqueous mother liquor filtrate;

membrane filtering the aqueous mother liquor filtrate to obtain a water permeate; and

transferring the water permeate to the water removal column.

11. The process of claim 10 , wherein reslurrying and purifying the dried filtercake of the dicarboxylic acid comprises:

reslurrying the solid filtercake of the aromatic dicarboxylic acid in an aqueous medium;

treating the aqueous slurry with hydrogen in the presence of a hydrogenation catalyst to obtain crystallization ready aromatic dicarboxylic acid slurry;

crystallizing the aromatic dicarboxylic acid in a series of at least two crystallization units;

filtering the crystallized aqueous slurry in a rotary pressure filter to obtain the final filtercake of the aromatic dicarboxylic acid and the aqueous mother liquor filtrate.

12. The process of claim 11 , wherein water of the reslurry aqueous medium is obtained from the condensate of the overhead vapors from the WRC.

13. The process of claim 10 , wherein the water for washing of the filtercake is water obtained from condensation of the overhead vapors from the WRC.

14. The process of claim 1 wherein the di-alkyl substituted aromatic compound is para-xylene and the aromatic dicarboxylic acid is terephthalic acid.