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Terephthalic acid

Terephthalic acid, with the C₈H₆O₄, is a white crystalline solid and the para of , also known by its IUPAC name benzene-1,4-dicarboxylic acid. It has a molecular weight of 166.13 g/mol, melts at approximately 427 °C under sealed conditions but sublimes at around 402 °C in air, and exhibits low in (about 15 mg/L at 20 °C) but dissolves in alkaline solutions. Industrially, terephthalic acid is produced on a massive scale through the catalytic air oxidation of in acetic acid solvent, typically using , , and as catalysts, followed by purification to yield high-purity terephthalic acid () suitable for applications. This accounts for the majority of global output, which reached approximately 84 million metric tons in 2022 and around 90 million tons in 2023, with continued growth due to demand in the sector. The compound's primary significance lies in its role as a key monomer for synthesizing (), a versatile used extensively in fibers, bottles, films, and packaging materials. The vast majority of terephthalic acid is directed toward and related polyesters, making it one of the most important commodity chemicals in the . Minor applications include wool processing as an neutralizer, additives in , and enhancements for certain antibiotics. Terephthalic acid is classified as an irritant to skin, eyes, and , with occupational exposure limits set at 10 mg/m³.

Properties

Physical properties

Terephthalic acid has the molecular formula C₈H₆O₄ and a molecular weight of 166.13 g/mol. It appears as a white crystalline solid at room temperature. The compound exhibits a melting point of 427 °C under sealed conditions, though it typically sublimes before melting at atmospheric pressure. Its boiling point is not applicable due to decomposition or sublimation prior to boiling. The density is 1.522 g/cm³ at 25 °C. Terephthalic acid is insoluble in , with a solubility of 0.0017 g/100 g at 25 °C (or approximately 15 mg/L at 20 °C). It shows slight solubility in alcohols such as (0.1 g/100 g at 25 °C) and . Solubility increases in polar aprotic solvents like (6.7 g/100 g at 25 °C) and (19.0 g/100 g at 25 °C), and it is soluble in alkaline solutions where it forms the corresponding . It remains insoluble in nonpolar solvents like and .
SolventSolubility (g/100 g at 25 °C)
0.0017
0.1
6.7
19.0
The crystal structure of terephthalic acid is triclinic (space group P-1), with two known polymorphs. Form II is the thermodynamically stable polymorph at and pressure, while form I is metastable but commonly observed. For form I, the lattice parameters are a = 7.730 Å, b = 6.443 Å, c = 3.749 Å, α = 91.99°, β = 99.09°, γ = 108.68°. Thermodynamic properties include a low of 6 × 10⁻¹¹ mm at 25 °C, indicating minimal . The constant heat capacity of the solid phase is 199.6 J/mol·K at 323 K.

Chemical properties

Terephthalic acid is a characterized by two groups with values of 3.54 and 4.46 at 25 °C, corresponding to the first and second steps, respectively. This acidity enables stepwise proton donation in aqueous solutions, with the initial dissociation represented by the equilibrium: \ce{C6H4(COOH)2 ⇌ C6H4(COO^-)(COOH) + H^+} The compound exhibits thermal stability up to approximately 400 °C, beyond which it undergoes decomposition, primarily yielding benzoic acid and carbon dioxide as key products. Due to the presence of the aromatic benzene ring, terephthalic acid demonstrates resistance to oxidation by mild oxidants, though it reacts with strong oxidizing agents such as permanganates or chlorine. In terms of reactivity, terephthalic acid readily undergoes esterification with alcohols under acidic conditions to form diesters, exemplified by its reaction with methanol to produce dimethyl terephthalate. It also forms salts upon reaction with bases, generating terephthalate anions such as disodium terephthalate, which are soluble in water and useful in various applications. Spectroscopically, terephthalic acid shows characteristic infrared absorption for the C=O stretch of the carboxylic groups at 1680 cm⁻¹, indicative of hydrogen-bonded dimers in the solid state. In ¹H NMR spectroscopy, the four equivalent aromatic protons appear as a singlet at approximately 8.1 ppm in deuterated solvents.

Molecular structure

Terephthalic acid, systematically named 1,4-benzenedicarboxylic acid, features a central benzene ring with two carboxylic acid (-COOH) groups attached at the 1 and 4 positions, positioned para to each other. This arrangement imparts high symmetry to the molecule, distinguishing it from its isomers: phthalic acid (1,2-benzenedicarboxylic acid) and isophthalic acid (1,3-benzenedicarboxylic acid), where the groups are ortho and meta, respectively. The para substitution results in a linear, extended structure that influences its packing and reactivity compared to the more compact ortho and angular meta forms. The isolated molecule is planar, with the ring and carboxylic groups lying in the same plane to maximize conjugation and minimize steric hindrance. It belongs to the C_{2v} , characterized by a twofold passing through the midpoint of the C2-C5 bond and the center of the ring, along with two vertical mirror planes: one containing the ring and the carboxylic carbons, and the other bisecting the ring perpendicularly. Key bond lengths from optimizations include aromatic C-C bonds averaging 1.39 , the ring-to-carboxyl C-C bond at approximately 1.50 , and the carbonyl C=O bond at about 1.20 ; these values align closely with experimental data from the . In the solid state, terephthalic acid crystallizes in a triclinic space group, forming intermolecular bonds between the groups of adjacent molecules. These O-H···O bonds, with typical O···O distances around 2.69 , create cyclic dimers as the primary , which extend into infinite ribbons along the molecular axis. The ribbons stack into two-dimensional sheets through additional weak C-H···O interactions and π-π stacking of the rings, contributing to the overall layered crystal packing that enhances stability. Terephthalic acid exhibits polymorphism, with two triclinic forms; form II is thermodynamically stable at , while form I is kinetically favored and commonly produced industrially.

History

Discovery

Terephthalic acid was first isolated in 1846 by French chemist Amédée Cailliot through the oxidation of with . Cailliot, a and , obtained a mixture of aromatic dicarboxylic acids from the reaction of with turpentine, a resin derived from pine trees containing like . Among these products were (the ortho ), (the meta ), and terephthalic acid (the ), with the latter distinguished by its high melting point and insolubility in common solvents. Cailliot named it "acide téréphtalique," initially referred to as paraphthalic acid to reflect its isomeric relationship to , which had been discovered a decade earlier by Auguste Laurent via oxidation of derivatives. Isolation and purification of terephthalic acid from the complex reaction mixture relied on fractional crystallization techniques. Cailliot dissolved the crude product in hot and allowed it to cool slowly, exploiting terephthalic acid's exceptionally low (less than 0.1 g/L at ) compared to the other isomers, which permitted selective of pure white crystals. This method yielded a substance that sublimed partially upon heating without melting, with observed at high temperatures, properties that set it apart from related acids. Early analyses confirmed its as C₈H₆O₄, though its precise structure remained unclear amid the evolving understanding of aromatic compounds; initial formulas were often expressed in doubled equivalents like C₁₆H₆O₈. The configuration of terephthalic acid relative to the and isomers was verified through mid-19th century studies involving tests and formations. Subsequent elucidation in the involved studies, where controlled oxidation and of and derivatives produced terephthalic acid consistently, aligning it with the emerging ring theory proposed by in 1865. These investigations established terephthalic acid as 1,4-benzenedicarboxylic acid, solidifying its place in .

Industrial development

In the 1940s, researchers J.R. Whinfield and J.T. Dickson at the Calico Printers' Association demonstrated significant interest in precursors, leading to their development of () through the reaction of terephthalic acid with . They filed a patent for this synthesis in 1941, marking a pivotal advancement that highlighted terephthalic acid's potential as a key monomer for high-performance polymers. Following , industrial scaling of terephthalic acid production accelerated as major chemical companies recognized its value in manufacturing. acquired rights to the PET patent for the and began commercial production, introducing Dacron fiber in 1950, while (ICI) licensed it for the rest of the world and launched Terylene in the the same year. These efforts transformed terephthalic acid from a laboratory curiosity into a cornerstone of the emerging industry. The saw a critical shift from batch oxidation es to continuous methods, enabling higher efficiency and purity in terephthalic acid output. The Mid-Century , developed in 1955 by of (later ), utilized air oxidation of in acetic acid with and catalysts, facilitating large-scale and reducing costs. This transition supported the rapid expansion of applications and solidified terephthalic acid's industrial viability. By the , terephthalic acid's market experienced substantial growth, closely linked to booming demand in the sector for fibers and the rise of in , particularly bottles. production capacity surged to meet these needs, with terephthalic acid reaching millions of tons annually by the decade's end, driven by its in durable, lightweight materials.

Production

Historical methods

Early production methods for terephthalic acid relied on the oxidation of , p-toluic acid, or related p-disubstituted derivatives using strong inorganic oxidants such as or . These approaches were typically batch processes conducted under conditions, often starting with -derived feedstocks since aromatics were predominantly sourced from until the 1920s. For instance, could be oxidized directly with , though yields were low and the process was not economically viable for large-scale commercial use due to side reactions and incomplete conversions. Similarly, p-methylacetophenone (derived from or fractions) was first treated with concentrated to form p-toluic acid, followed by oxidation with alkaline solution, achieving laboratory yields of 84–88% after acidification and . In the 1920s, alternative routes emerged utilizing products, particularly through the of —itself produced by the vapor-phase oxidation of from —to generate terephthalic acid precursors. was converted to dipotassium phthalate, which underwent thermal rearrangement to dipotassium terephthalate, followed by acidification to the ; these early attempts were explored as a means to leverage abundant ortho-isomer supplies but suffered from poor selectivity and complex separation challenges. Overall, such batch operations yielded 20–40% based on starting materials, accompanied by high waste streams including sludge from oxidations and nitrogen oxides from processes. Purification in these historical methods centered on by acidification of the reaction mixture with , followed by cooling, , and recrystallization from hot water or dilute acid to remove impurities like unreacted toluic acids or byproducts. The resulting terephthalic acid was typically washed with cold water and dried, though the process was labor-intensive and resulted in significant material losses. These pre-1950s techniques were limited by high operational costs stemming from expensive inorganic oxidants and low productivity of batch setups, as well as environmental concerns arising from the disposal of byproducts such as residues and acidic effluents. The inefficiencies prompted the shift toward more sustainable catalytic air oxidation methods in subsequent decades.

Amoco process

The process, originally developed in 1955 by Mid-Century Corporation and ICI with input from of Indiana (later ), was commercialized by in 1965 and represents the dominant industrial method for producing terephthalic acid from feedstock via catalytic liquid-phase oxidation. This process accounts for the majority of global terephthalic acid production due to its and . In the process, undergoes oxidation in a of acetic using air as the oxidant and a homogeneous catalyst system comprising and salts promoted by ions, typically at temperatures of 175–225 °C and pressures of 15–30 bar. The reaction proceeds through a free radical chain mechanism initiated by bromide-derived radicals, involving sequential formation of intermediates such as p-tolualdehyde, p-toluic , and 4-formylbenzoic , ultimately yielding terephthalic acid. Key propagating species include alkylperoxy and acylperoxy radicals (such as acetylperoxy radicals from oxidation), which facilitate C–H bond activation and oxygen insertion. The overall stoichiometry is represented by the equation: \mathrm{C_6H_4(CH_3)_2 + 3O_2 \rightarrow C_6H_4(COOH)_2 + 2H_2O} Significant challenges in the Amoco process include the formation of 4-carboxybenzaldehyde (CBA) as a persistent impurity, which arises from incomplete oxidation of the intermediate p-toluic acid and necessitates downstream purification steps like hydrogenation to achieve high-purity terephthalic acid suitable for polymerization. Additionally, the use of acetic acid as solvent leads to corrosion issues in reactor materials due to the acidic and oxidative environment, compounded by bromide's role in generating corrosive species like hypobromous acid. Efforts to mitigate solvent-related drawbacks have explored alternative reaction media, such as high-temperature water (including supercritical conditions) or ionic liquids, which offer reduced volatility, lower flammability risks, and potential while maintaining compatibility with the catalyst system. The process typically achieves conversions exceeding 98% and terephthalic acid yields of 90–95%, with post-oxidation polishing via or enhancing purity to over 99.99% for commercial applications.

Catalysts and promoters

In the industrial production of terephthalic acid via the oxidation of , the standard catalyst system consists of acetate and acetate, typically employed at an atomic Co/Mn ratio of about 5:1 to 40:1, leveraging the synergy between and ions, where facilitates the initial oxidation steps and promotes the decomposition of intermediates. Bromide promoters, such as (HBr) or methyl bromide (CH3Br), are essential for radical initiation in the , incorporated at concentrations of 0.1-2 wt% relative to the reaction mixture. These promoters generate radicals that abstract hydrogen from , accelerating the formation of intermediates and enhancing overall conversion efficiency. Additional additives include as an initiator to boost generation, particularly in low-bromide formulations, and heavy metal stabilizers like to prevent precipitation and maintain homogeneity. The combined Co/Mn/Br system significantly increases the reaction rate by 5-10 times compared to cobalt-only and reduces the key impurity 4-carboxybenzaldehyde () to levels below 200 in crude product, enabling high-purity . Variations in catalyst design include solvent-free oxidation systems using supported Mn-Co complexes, which achieve comparable yields without acetic acid solvent, and incorporation of co-catalysts like to further suppress side reactions and improve selectivity under milder conditions. These modifications are integrated into the process to enhance and reduce operational costs.

Alternative routes

One alternative route to terephthalic acid (TPA) involves the oxidation of p-toluic acid using air or oxygen in the presence of catalysts, bypassing the initial oxidation step from . This method employs nano or manganese-copper mixed catalysts in a bromine-free process, achieving high selectivity under milder conditions compared to traditional multi-stage oxidations. Similarly, terephthalaldehyde can be oxidized to TPA using air with iridium-based catalysts, converting the groups to carboxylic acids via a , with yields up to 76% reported in biomass-derived contexts. Another established route is the of (DMT), historically produced from petroleum-derived through sequential oxidation and esterification steps, or from coal-derived feedstocks in earlier processes. DMT is hydrolyzed under neutral or acidic conditions, often catalyzed by solid acids like Nb/HZSM-5, to high-purity TPA suitable for fiber-grade applications; this step typically achieves near-quantitative conversion in batch reactors. The full DMT route, including upstream , has been largely phased out in favor of direct TPA processes due to its 5-10% lower overall efficiency from multi-step losses and higher energy demands in esterification and recovery. Direct esterification in the DMT pathway—where p-toluic acid is esterified to methyl p-toluate before further oxidation to monomethyl terephthalate and then DMT—followed by provides an indirect path to TPA, emphasizing as a key for intermediate protection during oxidation. This approach was prominent in mid-20th-century production but declined with advances in direct oxidation technologies. Electrochemical oxidation of represents a promising alternative, involving two sequential anodic steps: initial C-H activation to p-tolualdehyde and p-toluic acid , followed by complete oxidation to TPA without corrosive promoters. This benign process uses divided cells with base electrolytes, delivering TPA in up to 80% yield at ambient conditions, reducing energy use and emissions relative to thermal methods. An emerging route utilizes catalytic dehydrogenation of , a saturated analog derived from bio-renewable or waste sources, to aromatize and oxidize the to TPA. This multi-step employs metal catalysts like Pd or Ru-Sn composites under oxidative conditions, offering potential for but currently limited by selectivity challenges in large-scale implementation.

Sustainable methods

Sustainable methods for terephthalic acid (TPA) production have emerged post-2010, focusing on bio-based feedstocks, enzymatic es, and alternative chemistries to minimize environmental impacts compared to traditional petroleum-derived routes. These approaches aim to reduce reliance on fossil resources and lower while maintaining high yields and scalability. One prominent bio-based route involves the of glucose to cis,cis-muconic acid using engineered microorganisms, followed by chemical and oxidation to TPA. This pathway utilizes renewable sugars from , achieving muconic acid yields of approximately 50 mol% from glucose in optimized microbial strains, with subsequent chemical conversion steps yielding up to 80% TPA from muconic acid. A comprehensive highlights the potential of this route for fully renewable TPA, with theoretical weight yields approaching 92% when integrated with bio-ethylene glycol for production. Enzymatic oxidation represents another green strategy, employing engineered bacteria to directly convert or related aromatics to TPA under mild conditions. For instance, metabolically engineered achieves high conversion yields (over 90%) of to TPA through sequential oxidation by expressed enzymes mimicking bacterial catabolic pathways. Similarly, enzymes, often from fungal or bacterial sources, facilitate selective oxidation of aromatic precursors, though integration into industrial bioprocesses remains under development for TPA-specific applications. CO₂ utilization offers a carbon-capture-integrated approach via catalytic of derivatives. A notable method involves the double of bisboronate ester using CO₂ and a catalyst, yielding TPA in a single step with good efficiency and avoiding fossil carbon inputs. This process leverages captured CO₂ as a C1 building block, potentially reducing net emissions in integrated facilities. To address solvent-related emissions in oxidation processes, ionic liquids serve as non-volatile alternatives to acetic acid, minimizing releases. These designer solvents enable aerobic oxidation of with comparable selectivity to conventional methods while enhancing safety and recyclability, thus reducing acetic acid emissions by replacing the traditional solvent system. Since the , companies like Virent have advanced toward commercialization through pilot-scale demonstrations of 100% renewable TPA via bio-paraxylene routes, including production of plant-based PET precursors and enabling prototype fully bio-based PET bottles as of 2021. As of , the bio-based paraxylene market is projected to grow significantly, valued at approximately $723 million, though full commercial-scale production remains in development. Overall, these sustainable methods can lower the by 50-80% relative to the Amoco process, depending on feedstock and process integration, as evidenced by assessments of bio-derived PET pathways.

Applications

Polyester production

Terephthalic acid (TPA) is primarily used in the production of polyethylene terephthalate (PET), a versatile polyester formed through the polycondensation reaction of TPA with ethylene glycol (EG). This process typically employs direct esterification, where TPA and EG are reacted to form bis(2-hydroxyethyl) terephthalate (BHET), followed by polymerization to yield high-molecular-weight PET. The production occurs via melt polymerization, in which the esterification step takes place at temperatures of 230–260 °C under moderate pressure (30–50 psig) to remove water, producing BHET. Subsequent polymerization proceeds at 270–300 °C under vacuum (0.1–1.0 mm Hg) to drive off EG and achieve the desired polymer viscosity. This two-stage process—esterification followed by polycondensation—results in PET with excellent mechanical properties suitable for various applications. The overall reaction is represented by the equation: n \ce{C6H4(COOH)2} + n \ce{HOCH2CH2OH} \rightarrow [\ce{-C6H4(COOCH2CH2O)-}]_n + 2n \ce{H2O} PET derived from TPA accounts for the majority of global polyester production, with approximately 90 million tons of TPA consumed annually for this purpose in 2023. The primary products include PET fibers used in textiles, which represent about 55% of the market; PET bottles for packaging, comprising around 30%; and PET films and resins for industrial uses, making up the remaining 15%. These applications leverage PET's strength, clarity, and recyclability, driving its widespread adoption in consumer and industrial sectors.

Other uses

Terephthalic acid serves as a key in the production of copolyesters such as polyethylene terephthalate glycol (PETG), which incorporates alongside for enhanced clarity and impact resistance. These copolyesters are widely utilized in applications, including food containers, bottles, and devices, due to their , chemical resistance, and processability. Terephthalate salts, derived from terephthalic acid, find applications in ion-exchange materials and pharmaceuticals. In ion-exchange systems, terephthalate anions enable selective separation and purification processes, such as distinguishing terephthalate from phthalate in . In pharmaceuticals, these salts contribute to formulations for and excipients, leveraging their stability and solubility properties. As a , terephthalic acid is incorporated into polymers (LCPs), which exhibit thermotropic behavior and high mechanical strength. These aromatic polyesters, often combined with monomers like and , are employed in , automotive components, and high-performance films for their low during processing and exceptional thermal stability. Through partial esterification, terephthalic acid is used to synthesize resins for coatings and adhesives. These resins provide durable finishes in coatings, offering resistance and to metal surfaces, while in hot-melt adhesives, terephthalic acid-based s enhance bonding strength and flexibility for and applications. In niche areas, derivatives of terephthalic acid, such as 2,5-dimethoxy terephthalic acid, are employed as in to improve whiteness and mask yellowing. Additionally, purified terephthalic acid acts as an analytical standard in chemistry for calibration in spectroscopic and chromatographic methods. These secondary applications collectively account for less than 5% of total terephthalic acid consumption, with the majority directed toward primary polyester production.

Safety

Health effects

Terephthalic acid exhibits low via oral exposure, with an LD50 greater than 5 g/kg in rats, indicating minimal risk from under typical conditions. It is classified as a irritant (GHS Category 2, H315) and causes serious eye irritation (GHS Category 2A, H319), potentially leading to redness, pain, and temporary upon direct contact. Dermal acute toxicity is also low, with an LD50 exceeding 2 g/kg in rabbits. Chronic exposure to terephthalic acid dust via may cause , including coughing, wheezing, and potential progression to in severe cases. Repeated or prolonged can lead to ongoing without of systemic at low levels. Regarding carcinogenicity, terephthalic acid has not been classified by the International Agency for Research on Cancer (IARC) regarding its carcinogenic potential in humans or experimental animals. Upon absorption, terephthalic acid is not significantly metabolized and is rapidly excreted primarily unchanged via , with over 94% recovery in rats following . Minor conjugation may occur, but the parent compound predominates in urinary , facilitating quick elimination and limiting . Occupational exposure limits for terephthalic acid are established to prevent , with a time-weighted average () of 5 mg/m³ for the inhalable fraction recommended by the German MAK Commission. The American Conference of Governmental Industrial Hygienists (ACGIH) (TLV) is set at 10 mg/m³ as TWA for total dust, though stricter limits apply in some jurisdictions to account for respirable fractions. In animal studies, high-dose to terephthalic acid has shown potential developmental effects, such as reduced pup weight and survival in rat reproduction studies at doses exceeding 500 mg/kg/day, though no adverse outcomes were observed at lower levels relevant to . These findings suggest vulnerability in developing organisms under extreme conditions, but terephthalic acid is not considered a primary reproductive .

Handling precautions

Terephthalic acid requires storage in cool, dry, well-ventilated areas within tightly sealed containers to minimize moisture absorption, which can cause caking and degradation of the material. Incompatible materials such as strong oxidizing agents should be kept separate to prevent potential reactions. Safe handling involves the use of (PPE) to prevent exposure to dust, which can cause irritation; this includes gloves with a minimum breakthrough time of 480 minutes, safety goggles or glasses compliant with EN 166 or equivalent standards, and particulate respirators (e.g., filter type P1 or NIOSH-approved) when dust levels may exceed recommended limits. Processing areas must feature local exhaust ventilation to control airborne dust concentrations, and good industrial hygiene practices, such as washing hands after handling and changing contaminated clothing, are essential. For transportation, terephthalic acid is not classified as a dangerous good under regulations such as , IATA, IMDG, or ADG, with proper shipping name "Terephthalic acid" and no assigned or packing group; however, measures to mitigate combustible risks, such as avoiding ignition sources, are recommended during loading and unloading. In the event of a spill, evacuate non-equipped personnel, eliminate ignition sources, and use spark-proof tools to sweep or vacuum (with filtration) the material into sealed containers, avoiding generation and to prevent formation of a difficult-to-handle or environmental release. Contaminated surfaces should then be cleaned with dry methods. Terephthalic acid is registered under the European REACH ( 1907/2006) with dossier number 15563, ensuring compliance with safety assessments for manufacture and use. In the United States, handling adheres to OSHA standards for combustible under 29 CFR 1910.1000 and related guidelines, including permissible limits for nuisance (TWA 10 mg/m³ as per ACGIH reference).

Environmental impact

Biodegradation

Terephthalic acid (TPA) is readily biodegradable in standard aerobic ready biodegradability tests using non-adapted microbial inocula, such as those outlined in Guideline 301, achieving 60-85% degradation within 28 days; microbial adaptation further enhances rates for complete mineralization. However, under favorable conditions with specialized bacterial strains, TPA is efficiently degraded aerobically as the sole carbon and energy source. Key degraders include species from the genera Pseudomonas, Comamonas, and , which metabolize TPA through the protocatechuate pathway. In this pathway, TPA undergoes initial dioxygenation by terephthalate 1,2-dioxygenase to form cis-1,2-dihydroxy-3,5-cyclohexadiene-1,4-dicarboxylic acid, followed by dehydrogenation to protocatechuate, which is then cleaved by protocatechuate 4,5-dioxygenase and further broken down via the β-ketoadipate route to central metabolites like and . These can achieve near-complete degradation (up to 97-100%) of TPA concentrations around 100-1000 mg/L within hours to days, depending on strain and conditions. Anaerobic degradation of TPA is generally slower and less efficient than aerobic processes, often requiring the presence of co-substrates like or benzoate to mitigate inhibition and support syntrophic microbial communities. Under conditions, TPA is converted primarily to CO₂ and through to (7-carboxyheptanoyl)- or pathways involving syntrophic bacteria such as Syntrophobacter species, with degradation rates improved by additives like nanoparticles that enhance . This process is commonly applied in but remains rate-limited by TPA's to methanogens at high concentrations. In environments, the of TPA ranges from less than 1 day to several weeks under aerobic conditions, varying with microbial activity and substrate availability; optimal degradation occurs with of 10-50 days when conditions support active consortia. Degradation rates are enhanced by environmental factors including above 6 (ideally 7.0), temperatures between 20-30°C, and adequate aeration or nutrient availability, as demonstrated in studies with isolated strains achieving 97.6% degradation under these parameters. This contributes to the environmental fate of TPA released from waste , though polymer degradation itself is slower.

Emissions and waste management

The production of terephthalic acid (TPA), particularly via the process involving oxidation in acetic acid with cobalt-manganese-bromide catalysts, generates key emissions including volatile organic compounds (VOCs) such as , acetic acid, and , along with (). Uncontrolled VOC emissions from the reactor vent can reach approximately 15 g per kg of TPA, while and drying vents contribute about 1.9 g/kg, vents 1.1 g/kg, and product vents 1.8 g/kg; overall, these can total 1-5 kg per ton of TPA without mitigation. CO emissions are notable from the reactor (17 g/kg) and product transfer (2 g/kg). , primarily from product handling, are around 0.7 g/kg TPA. As of 2025, research into bio-based and recycled TPA production aims to reduce dependency and emissions, with recycled TPA cutting carbon emissions by up to 48% compared to conventional methods. Wastewater streams, particularly the mother liquor from purification, exhibit high (COD) levels, often ranging from 7,000-8,000 mg/L or higher (up to 100,000-150,000 mg/L in some cases), due to dissolved organics like terephthalic acid residues, p-toluic acid, and acetic acid. These effluents, generated from absorbers and units, are typically treated through a combination of pretreatment (e.g., coagulation-flocculation) followed by biological oxidation processes, achieving COD removals of 97% or more and BOD removals exceeding 99% in aerobic systems. Solid wastes include residues such as spent cobalt-manganese catalysts and filtration cakes from purification, which are managed through and to minimize disposal. Catalyst techniques, including electrolytic and regeneration from oxidation residues, enable recycling rates often exceeding 90% by reclaiming metals for reuse in the process, reducing the need for virgin materials and generation. Regulatory frameworks address these emissions stringently. In the United States, the Environmental Protection Agency (EPA) promotes controls under AP-42 guidelines, targeting reductions through achieving over 99% efficiency and carbon adsorption at 97%, effectively limiting stack emissions to below 0.1 g/m³ in compliant facilities. In the , Best Available Techniques (BAT) Reference Documents for large-volume organic chemicals specify BAT-associated emission levels (BAT-AELs) for VOCs of 5-20 mg/Nm³ from oxidation off-gases, with capture efficiencies approaching 99% via integrated systems, alongside wastewater COD limits of 50-150 mg/L post-treatment. Mitigation strategies emphasize prevention and end-of-pipe controls, including wet scrubbers for acid gases, (thermal or catalytic) for VOCs and , and closed-loop of acetic acid solvent (recovering over 99% via ) to minimize both emissions and volumes. Adsorption using or zeolites captures residual VOCs from vents, while source segregation and pretreat wastewater to enhance biological treatability, collectively reducing environmental releases by orders of magnitude compared to uncontrolled processes.

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