Butadiene, also known as 1,3-butadiene, is an important industrial chemical that serves as a key building block in the production of numerous materials. Used globally in enormous volumes each year, butadiene touches many aspects of modern life through its versatile downstream applications. In this article, we will explore butadiene's uses, production methods, and health and environmental impacts.

Introduction to Butadiene

Butadiene is a colorless gas with a mild aromatic odor. It is a conjugate diene, meaning it contains two carbon-carbon double bonds that can participate in addition reactions. The position of the double bonds - one between the first and second carbons and the other between the third and fourth carbons - gives butadiene its systematic name of 1,3-butadiene. This structure allows butadiene molecules to polymerize, or link together, in various ways. Its reactivity makes butadiene quite valuable for producing polymers, synthetic rubbers, and other chemical derivatives.

Major Applications of Butadiene

Synthetic Rubbers
Styrene-butadiene rubber (SBR) is the largest application for Butadiene. SBR is used primarily to manufacture tires and shoe soles due to its excellent resilience, flexibility, and abrasion resistance. Global demand is over 6 million tons per year.
Polybutadiene rubber (PBR) is the second most important butadiene-based synthetic rubber. PBR is used in tires, construction materials, and adhesive applications where high strength and flexibility are needed.

Plastics and Resins
Polybutyrate resins and copolymers are used to make packaging films and coatings. Polybutyrate possesses good clarity, heat resistance, and machinability. Butadiene is also used to make plastic casings for electronics and appliances.
Nitrile rubber containing butadiene provides chemical and oil resistance for hoses, seals, and gaskets.

Other Applications
Butadiene is also consumed in manufacturing nylon fibers, latex paints, paper coatings, and fuel additives. Recent research explores utilizing it to make biodegradable plastics. With further development, butadiene may find use in 3D printing filaments and carbon fiber composites as well.

Production Methods for Butadiene
Almost all commercial butadiene is produced through the selective catalytic dehydrogenation of normal butane in a vapor-phase process. The dominant production route involves heating a butane feedstock over an acidic alumina catalyst at high temperatures. This endothermic process selectively removes hydrogen atoms from the butane molecule to form butadiene and hydrogen gas.

Alternate production methods include oxidizing n-butane or extractive distillation of C4 fractions from cracking of petroleum or natural gas liquids. However, catalytic dehydrogenation currently accounts for over 95% of global butadiene supply due to its higher yield and selectivity. Major manufacturing plants are located near sources of butane, such as natural gas fields and oil refineries. The United States, China, Korea and Western Europe contain many of the world's large-scale butadiene production facilities.

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