Acrylic acid, also known as propenoic acid, is an organic compound with the formula CH2=CHCOOH. It is a colorless, volatile liquid and soluble in organic solvents. Acrylic acid finds extensive use as a co-monomer in the production of plastics, coatings, adhesives and sealants for various industrial applications.
Manufacturing of Acrylic Acid
Acrylic acid is primarily produced via the catalytic oxidation of propylene. In the industrial process, propylene is passed through an air separation unit to obtain high purity oxygen. This oxygen is then fed into the catalyst bundle along with propylene at high temperatures ranging between 300 to 450 degree Celsius. Commonly used catalysts are manganese, cobalt, chromium and bromine compounds supported on acidic alumina or silica. The reaction is exothermic and the heat of reaction is removed by circulating cooling water inside the reactor shell. The gaseous products from the reactor contain acrylic acid, acetic acid, carbon dioxide and water vapor which are then subject to further purification steps.
Purification of Crude Acrylic Acid
The crude product stream obtained from the reactor contains several impurities and needs to be purified. It is first washed to remove acetic acid and other organic byproducts. Then the stream is passed through an absorption column where it is absorbed using water as solvent. Acrylic acid forms an azeotrope with water and gets separated. The bottom stream contains high purity acrylic acid product. Trace impurities if any are removed using charcoal treatment. The purified acrylic acid obtained is of polymerization grade quality with purity levels greater than 99%.
Uses and Demand Outlook
As mentioned earlier, acrylic acid serves as an important co-monomer in the production of various polymers and plastics. Some key application areas are discussed below:
- Polyacrylates: Acrylic acid is polymerized to form polyacrylates or polymethyl methacrylates. These find widespread application in surface coatings, adhesives and sealants market.
- Super Absorbent Polymers (SAP): Acrylic acid is a primary raw material in the manufacture of SAP which are added to baby diapers, adult incontinence products and feminine hygiene items to absorb large volumes of liquid.
- Ammonium/Sodium Polyacrylates: These are water soluble resins made from partial neutralization of polyacrylic acid. They are used as thickeners in paints, ceramics, construction chemicals, textiles, paper, cosmetics etc.
- Fabric Softeners: Acrylates provide a antistatic and wrinkle resistance property to fabrics when used in softeners and detergents.
The global acrylic acid market volume stood at 6.7 million tons in 2021 and demand is projected to grow at over 4% annually through 2030 driven by the expanding end use industries especially coatings, adhesives and super absorbent polymers segments in developing nations. China dominates the current global capacity while demand growth is expected to be higher in Southeast Asia and India in the coming years owing to industrialization.
acrylic acid is an important organic acid with widespread industrial significance as a co-monomer in plastics, coatings and polymers production. Future demand outlook remains positive with the compound's increasing use in end products ranging from disposable diapers and feminine hygiene items to construction chemicals and fabric softeners. The versatility of its applications across industries ensures stable growth opportunities for players involved in acrylic acid manufacturing and trade.
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