Acetic acid is produced industrially both naturally via bacterial
fermentation and synthetically. Acetic acid can be purified via
fractional freezing using an ice bath. The water and other
impurities will remain liquid while the acetic acid will
precipitate out. As of 2003–2005, total worldwide production of virgin acetic acid was estimated at 5 Mt/a (million tonnes per year), approximately half of which was produced in the United States. European production was approximately 1 Mt/a and declining, while Japanese production was 0.7 Mt/a. Another 1.5 Mt were recycled each year, bringing the total world market to 6.5 Mt/a. Since then, the global production has increased from 10.7 Mt/a in 2010 to 17.88 Mt/a in 2023. The two biggest producers of virgin acetic acid are
Celanese and
BP Chemicals. Other major producers include
Millennium Chemicals,
Sterling Chemicals,
Samsung,
Eastman, and .
Methanol carbonylation Most acetic acid is produced by methanol
carbonylation. In this process,
methanol and
carbon monoxide react to produce acetic acid according to the equation: : The process involves
iodomethane as an intermediate, and occurs in three steps. A
metal carbonyl catalyst is needed for the carbonylation (step 2).
Acetaldehyde oxidation Prior to the commercialization of the Monsanto process, most acetic acid was produced by oxidation of
acetaldehyde. This remains the second-most-important manufacturing method, although it is usually not competitive with the carbonylation of methanol. The acetaldehyde can be produced by
hydration of acetylene. This was the dominant technology in the early 1900s. Light
naphtha components are readily oxidized by oxygen or even air to give
peroxides, which decompose to produce acetic acid according to the
chemical equation, illustrated with
butane: : Such oxidations require metal catalyst, such as the
naphthenate salts of
manganese,
cobalt, and
chromium. The typical reaction is conducted at
temperatures and pressures designed to be as hot as possible while still keeping the butane a liquid. Typical reaction conditions are and 55 atm. Side-products may also form, including
butanone,
ethyl acetate,
formic acid, and
propionic acid. These side-products are also commercially valuable, and the reaction conditions may be altered to produce more of them where needed. However, the separation of acetic acid from these by-products adds to the cost of the process. Similar conditions and
catalysts are used for butane oxidation, the
oxygen in
air to produce acetic acid can oxidize
acetaldehyde. : It is thought to be competitive with methanol carbonylation for smaller plants (100–250 kt/a), depending on the local price of ethylene.
Oxidative fermentation For most of human history, acetic acid bacteria of the genus
Acetobacter have made acetic acid, in the form of vinegar. Given sufficient oxygen, these bacteria can produce vinegar from a variety of alcoholic foodstuffs. Commonly used feeds include
apple cider,
wine, and fermented
grain,
malt,
rice, or
potato mashes. The overall chemical reaction facilitated by these bacteria is: : A dilute alcohol solution inoculated with
Acetobacter and kept in a warm, airy place will become vinegar over the course of a few months. Industrial vinegar-making methods accelerate this process by improving the supply of
oxygen to the bacteria. Nowadays, most vinegar is made in submerged tank
culture, first described in 1949 by Otto Hromatka and Heinrich Ebner. In this method, alcohol is fermented to vinegar in a continuously stirred tank, and oxygen is supplied by bubbling air through the solution. Using modern applications of this method, vinegar of 15% acetic acid can be prepared in only 24 hours in batch process, even 20% in 60-hour fed-batch process.
Anaerobic fermentation Species of
anaerobic bacteria, including members of the genus
Clostridium or
Acetobacterium, can convert sugars to acetic acid directly without creating
ethanol as an intermediate. The overall chemical reaction conducted by these bacteria may be represented as: : These
acetogenic bacteria produce acetic acid from one-carbon compounds, including methanol,
carbon monoxide, or a mixture of
carbon dioxide and
hydrogen: : This ability of
Clostridium to metabolize sugars directly, or to produce acetic acid from less costly inputs, suggests that these bacteria could produce acetic acid more efficiently than ethanol-oxidizers like
Acetobacter. However,
Clostridium bacteria are less acid-tolerant than
Acetobacter. Even the most acid-tolerant
Clostridium strains can produce vinegar in concentrations of only a few percent, compared to
Acetobacter strains that can produce vinegar in concentrations up to 20%. At present, it remains more cost-effective to produce vinegar using
Acetobacter, rather than using
Clostridium and concentrating it. As a result, although acetogenic bacteria have been known since 1940, their industrial use is confined to a few niche applications. == Uses ==