1.

INTRODUCTION

Methyl ethyl ketone is a colourless, volatile, highly flammable liquid with a fruity odour similar to acetone. Methyl ethyl ketone is produced naturally at low levels by some trees, bacteria and seaweeds. It is also a natural component of a wide range of foods (Health Protection Agency).

Ketones are organic compounds containing one or more carbonyl groups bound to two carbon atoms and are represented by the general formula:

O R

R C

Based on the hydrocarbon (R, R) groups attached to the carbonyl group, ketones can be classified. MEK has the molecular structure: CH3 CO C2 H5. It is unsymmetric or mixed aliphatic ketone. Its IUPAC name is 2-butanone. 2-Butanone, methyl ethyl ketone, MEK, is the 2nd link in the homologous series of aliphatic ketones and next to acetone, the most important commercially produced ketone.

It is commercially produced by dehydrogenation of the secondary butyl alcohol. It is analogus to the production of actone by dehydrogenation of isopropyl alcohol on copper or zinc or bronze catalyst at 400 500 0C. At 80-95% sec butylalcohol conversion, MEK selectivity is greater than 95%. Butenes (dehydration) and higher ketones (auto condensation) are the by-products. Methyl Ethyl Ketone (MEK) is a low boiling, chemically stable compound also known as 2butanone. MEK is a flammable, colourless liquid possessing a typical ketonic odor. It has very good solvent properties, a fast evaporation rate, and is miscible with organic solvents. MEK is an excellent solvent for a variety of resin systems used in the preparation of paints and lacquers.

Methyl Ethyl Ketone (MEK) is a low boiling, chemically stable compound also known as 2butanone. MEK is a flammable, colourless liquid possessing a typical ketonic odor. It has very good solvent properties, a fast evaporation rate, and is miscible with organic solvents. MEK is an excellent solvent for a variety of resin systems used in the preparation of paints and lacquers.

1.1

Economic aspects

Asia (primarily China and Other Asia) has gained market share over the years and will continue to do so during 20112016, driven by continued economic growth in these emerging markets. A dip in market share in 2011 reflects a drop in Japanese consumption related primarily to the March 2011 earthquake and tsunami.

The following pie chart shows world consumption of methyl ethyl ketone:

Coating solvents continue to consume the majority of MEK. Worldwide, almost 50% of MEK was consumed for this application in 2011. There will be little change in the world MEK market breakdown by 2016. However, there are slight regional variations in the consumption pattern. Although printing inks make up only 8% of the MEK market, this application will experience the second-highest growth rate during 20112016, especially in China.

World MEK consumption is forecast to grow at an average annual rate of about 3.5% during 20112016. Most of that growth will come from Asia Pacific, especially China where its use in most applications (coatings, adhesives, artificial leather and printing inks) is expected to grow at an average annual rate of over 8% during 20112016. MEK consumption in the developed regions will increase only modestly during 20112016.

Escalating raw material costs prompted MEK price increases through most of 2008 before the economic crisis brought them down in 2009. With improved demand and rising feedstock costs, prices started to increase near the middle of 2009. Price increases in 2010 were attributed primarily to a tight supply situation that was exacerbated in early to mid-2011 by the March 2011 disaster in Japan. Prices hit record highs in 2011. As 2011 ended and 2012 began, weaker demand brought prices back down (IHS Chemical).

1.2

Production and manufacturing process

The main commercial route to MEK is the dehydrogenation of secondary butanol. Some companies employ sulphuric acid hydration of n-butene to make the secondary butanol.

The alcohol vapour is fed into a multi-tubular reactor containing zinc or copper oxides as catalysts. The reaction takes place at 400-500oC and pressures of less than 4 bars. Liquid phase technology is also employed in Europe using Raney nickel or copper chromate at 150oC. Hydrogen is flashed off and the condensate is dehydrated by fractionation. The MEK phase separates from the water-ketone azeotrope obtained and is distilled.

A newer technology involves the direct oxidation of n-butene in solution using palladium and cupric chlorides as catalysts. MEK can also be made as a by-product in butane-based acetic acid manufacture. MEK could also become available as a byproduct from a new phenol process being developed by Shell. This process produces MEK and acetone as byproducts and there is the potential to change the acetone/MEK ratio within reasonable limits to meet varying market demands (Chemical Report, 2007).

Figure 1.2 illustrates the production and use of MEK. Major end-users of MEK include protective coating solvents (61 percent), adhesives (13 percent), and magnetic tapes (10 percent). Vinyls are the primary resins that employ MEK as a solvent. Methyl ethyl ketone is commonly used as a solvent in rubber cements, as well as in natural and synthetic resins for adhesive use. It is also the preferred extraction solvent for dewaxing lube oil and is used in printing inks.

Overall, the projected use of MEK is expected to gradually decline during the 1990s. The growing trend towards water-based, higher-solids, and solventless protective coatings, inks, and adhesives should reduce the demand for MEK. The installation of solvent recycling facilities will also reduce requirements for fresh solvent production. Although MEK is favored as a solvent due to its low density, low viscosity, and high solvency, its recent addition on the EPAs hazardous air pollutants list will likely cause potential users to consider other comparative solvents such as ethyl acetate (Michael, J et al., 1985).

Figure 1.2: MEK production and the uses

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Ketone.

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Michael, J et al. (1985). Ambient Air Pollution from Industrial Sources: A Reference Handbook. World Health Organization, Regional Office for Europe. Elsevier Science Publishers. New York. Retrieve 19 May, 2013 from http://www.epa.gov/ttnchie1/le/mek_l&e.pdf