1. Overview of the three process alternatives of glyphosate production
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- Joanna Ann Fletcher
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1 Supplementary 1. verview of the three process alternatives of glyphosate production There are three commercialized processes for producing glyphosate in China. Fig. 1 is a schematic diagram of the three commercialized processes. HC process P + Cl 2 CH 4 + H 3 Pt HC(aq.) HC (cyanohydrin) C H C (IDA) H 3 ah(aq.) H Ca Ca (DSIDA) PCl 3 HC(aq.) P (PMIDA) CH CH a 2 Mo 4 H 2 2 FeS 4 P H H Glyphosate (PMG) DEA process + H3 H 2CH 2CH 2H (CH 2CH 2H) 3 H CH 2 H CH 2 H (Diethanolamine) DEA ah(aq.) Cu based-cat H 2 Ca H Ca (DSIDA) P + Cl 2 PCl 3 HC(aq.) P (PMIDA) CH CH a 2 Mo 4 H 2 2 FeS 4 P H H Glyphosate (PMG) Glycine process P + Cl 2 CH 3 CH Cl 2 /Ac 2 ClCH 2 CH PCl 3 + CH 3 H (HC)n HCl Et 3 /CH 3 H H 4 Cl H 3 /CH 3 H H 2 CH 2 CH (Glycine) HCl CH 3 Cl H 3 C P CH 3 H (DMPP) H 3 C H 3 C P CH 2 CH 3 CH HCl (31%) P H H Glyphosate (PMG) Fig. 1 Schematic diagram of commercialized production processes of glyphosate in China (1) The HC process The HC process is started with natural gas as one of the raw materials, and HC and IDA are key intermediates. At the beginning, HC is synthesized with natural gas and ammonia, catalyzed by Platinum via the Andrussow process [ote 1]. Then HC reacts with formaldehyde to get cyanohydrin, followed by cyanohydrin reacts with ammonia to get iminodiacetonitrile (IDA) [ote 2]. IDA is hydrolyzed in aqueous sodium hydroxide to get disodium iminodiacetic acid (DSIDA), and ammonia byproduct is recovered and recycled for IDA preparation. The DSIDA, phosphorous chloride (PCl 3 ), and formaldehyde are reacted in aqueous solution to get -phosphonomethyliminodiacetic acid (PMIDA) via the Mannich reaction [ote 3]. At last, PMIDA is oxidized to get the target product glyphosate. The share of this process had been rapidly increased since 2007, and its output capacity took about a 1
2 20% share of total glyphosate output in China. (2) The DEA process The DEA process is started from ethylene oxide (E). E is reacted with liquid ammonia in a continuous tubular reactor to get the mixture of monoethanolamine (MEA), diethanolamine (DEA), and triethanolamine (TEA). The mixture is rectified to produce three products [ote 4]. The ratio of MEA, DEA, and TEA can be adjusted based on the market demands. DEA is catalytically oxidized to disodium iminodiacetic acid (DSIDA) with a copper-based catalyst under basic condition in aqueous solution [ote 5]. Then DSIDA, PCl 3, and formaldehyde are reacted via the Mannich reaction similar with that of the HC process to get PMIDA. At last, PMIDA is oxidized to get the target product glyphosate. The catalytic dehydrogenation of diethanolamine is the key step of DEA process. Monsanto invented the diethanolamine catalytic dehydrogenation technology and awarded a Presidential Green Chemistry Challenge Award. The capacity share of the DEA process in China is nearly 20 percent. (3) The glycine process The glycine process is the most widely used process in China, taking a 60% share of the glyphosate output [ote 6]. The glycine process is started with glycine, dimethylphosphonate (DMPP) and paraformaldehyde as key raw materials. At the beginning, paraformaldehyde undergoes depolymerization catalyzed by triethylamine in anhydrous methanol. Successively it reacts with glycine and DMP via the Mannich reaction, then concentrated aqueous hydrochloric acid (31%) is added to the solution obtained above and heated to reflux, thus the target product glyphosate is formed. This process is almost a one-pot process. Glycine is mainly prepared by reaction of chloroacetic acid with ammonia in methanol solution. Chloroacetic acid is synthesized by chlorination of acetic acid with chlorine. DMPP is prepared by reaction of PCl 3 with anhydrous methanol via the Arbuzov reaction. Methylchloride, which is the core byproduct both in DMPP preparation and hydrolysis of the Mannich reaction products, is recovered and reused as a start material for organic silicon products. Glycine can also be prepared with ammonia and cyanohydrin [ote 7]. As for the three manufacturing processes, the glycine process is the pioneer commercialized in China, the DEA process and HC process are commercialized in a late stage. The Andrussow process for HC production and the cyanohydrin 2
3 preparation process have been well-done in China with a long history. In 2005, a great improvement of IDA manufacturing from cyanohydrin and ammonia made the HC process a grand step forward in China, and its output increased rapidly. xidation of PMIDA to PMG is another one of the most important cores of the CH4-HC-IDA process and DEA process. The evolution footsteps of PMIDA oxidation to PMG is as following: concentrated sulfuric acid oxidation transition metal catalytic hydrogen peroxide oxidation noble metal catalytic hydrogen peroxide oxidation active carbon catalytic hydrogen peroxide oxidation noble metal loaded active carbon catalytic air or oxygen oxidation [ote 8]. Up to now, the noble metal loaded active carbon catalytic air or oxygen oxidation process is the most effective one with high selectivity, which represents the developing trend of PMIDA oxidation to PMG. A sodium tungstate catalyzed hydrogen peroxide oxidation process is generally applied in China, with a total oxidation yield of 87%. The catalytic air oxidation process is much cleaner than sodium tungstate catalytic oxidation process. Recently, the commercialization of catalytic air oxidation of PMIDA to PMG in China is in a pilot scale with several hundred tonnes a year. ote 1: Refer to a representative patent of the HC manufacture process: US ote 2: Refer to representative patents of the IDA manufacture process: US , US , and US ote 3: Refer to a few representative patents of the PMIDA manufacturing process: US , US , US , and C A. ote 4: Refer to a few representative patents of the synthesis of MET, DEA, and TEA in a continuous tubular reaction manner with E and liquid ammonia as starting materials: US , C , C A, C A, and C A. ote 5: Refer to a few representative patents of catalytic dehydration of the DEA process: US , US , US , US , and C A. ote 6: Refer to two representative patents of the glycine process for glyphosate: C and C ote 7: Refer to two representative patents of glycine preparation: US and ZL ote 8: Refer to a few representative patents of PMIDA oxidation to PMG process: US , 3
4 US395002, US , C , EP , US , C , US , and W
5 2. Mass balance analysis of the three alternatives Table S1 Mass balance analysis of the HC process Unit Input utput CH 4 H 2 S 4 HC H 3 ah(aq.) P Cl 2 H 2 2 PMG (H 4 ) 2 S 4 umber of atoms C / in molecular H / / / S / 1 1 P / 1 1 Cl / 2 a / 1 Molecular weight / Purity % Material consumption per PMG output kg/t E Factor kg/kg 4.3 Carbon element kg itrogen element kg Phosphorous element kg Chlorine element kg
6 Table S2 Mass balance analysis of the DEA process Unit Input utput E H 3 ah(30%) Cu-Cat P Cl2 HC(30%) H 2 2 (30%) Cat FeS 4 PMG MEA TEA umber of atoms C in molecular H S 1 P 1 1 Cl 2 Br B K a 1 Fe 1 Molecular Weight Purity 99% 99% 30% 99% 99% 99% 30% 30% 99% 95% 95% 99% 99% Material consumption per PMG output kg/t E factor kg/kg Carbon element kg itrogen element kg Phosphorous element kg Chlorine element kg
7 Table S3 Mass balance analysis of the glycine process Unit Input utput HAc Ac 2 Cl 2 (CH 2 ) 6 4 H 3 CH 3 H PFA P Et 3 ah HCl PMG CH 3 Cl CH 2 (CH 3 ) 2 H 4 Cl umber of C / atoms H / in molecular / / S / P / 1 1 Cl / a / 1 Molecular weight / Purity % Material consumption kg/t per PMG output E Factor kg/kg 5.8 Carbon element kg itrogen element kg Phosphorous element kg Chlorine element kg
8 Table S4 Sensitivity of the weight of economic metrics Criteria Metrics HC DEA Glycine Process process Process Cost index weighted 20% Cost index weighted 30% HC DEA Glycine HC DEA Process process Process Process process Synthetic complexity umber of chemistry steps Process material PMI intensity (PMI) Carbon input per glyphosate output itrogen input per glyphosate output Phosphorous input per glyphosate output Chlorine input per glyphosate output Efficiency of Carbon efficiency key elements itrogen efficiency Phosphorous efficiency Energy efficiency Energy consumption per glyphosate output ature of waste Elemental carbon in waste per glyphosate output Elemental nitrogen in waste per glyphosate output Elemental phosphorous in waste per glyphosate output Elemental chlorine in waste per glyphosate output Economic metrics Cost of raw material for producing 1,000 kg of glyphosate Toxicity of materials LD 50 or LC 50 of the most toxic material used Total score Glycine Process 8
9 Fig. S1 Price (yuan/tonne) of glyphosate in WYCA during 2006 to 2012 ote: WYCA is the top one producer of glyphosate in China with glycine process. Its main page is Accessed on April 23, Source: Accessed on April 23,
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