Acrolein and Derivatives

Abstract Approximately 350 kt of acrolein are produced annually, worldwide. Most demand for acrolein is in the preparation of methionine. Much larger quantities of crude acrolein are produced as an intermediate in the production of acrylic acid. Most of the acrylic acid produced worldwide is by the captive oxidation of acrolein. Of a wide variety of other derivatives, only a few (glutaraldehyde, pyrans) are made in 1000 ton per year or larger quantities, although the potential exists for many others. The narrow commercial markets and acrolein's extreme reactivity and toxicity have limited producers to only a few. Acrolein's toxicity, which has limited the development of derivative products and processes, provides its major direct use, as a biocide and sulfur scavenger in the petroleum industry, and as a herbicide in irrigation systems. Acrolein is produced by the vapor‐phase oxidation of propylene, and the catalyst developments which are responsible for today's processes have been driven primarily by the acrylic acid manufacturers. The chemical technology for manufacturing acrolein along with the pertinent analytical methods and health, safety, and environment issues surrounding acrolein manufacture and storage are discussed. The chemistry to produce major acrolein derivative products as well as a variety of potentially useful acrolein derivatives is summarized.