Pharmaceutical intermediate synthesis system

Abstract

The invention provides a medical intermediate synthesis system, which relates to the technical field of medical intermediate synthesis, and comprises a reaction kettle, a raw material feeding module, a catalyst adding module, a stirring module, a temperature control module, a pressure adjusting module, a product separation module, a tail gas treatment module, an online monitoring module and a control system, the reaction kettle adopting a novel corrosion-resistant alloy material and a special anti-sticking coating reduces the adhesion and residue of reactants and shortens the cleaning time of the reaction kettle, so that the effective reaction time is increased, the high-precision raw material feeding module and the catalyst adding module are arranged, the accurate proportioning and uniform dispersion of the reaction materials are ensured, and the production efficiency is improved. The reaction rate and the conversion rate are improved, side reactions are reduced, the synthesis period is further shortened, ideal reaction conditions can be rapidly achieved and stably maintained through the efficient temperature control module and the efficient pressure adjusting module, and the reaction process is further accelerated.

Description

Technical Field

[0001] The invention belongs to the technical field of pharmaceutical intermediate synthesis, and more specifically, particularly relates to a pharmaceutical intermediate synthesis system. Background Art

[0002] In the field of pharmaceutical intermediate synthesis, efficient, precise and controllable synthesis systems are essential for producing high-quality pharmaceutical intermediates. However, traditional pharmaceutical intermediate synthesis systems have many problems and challenges.

[0003] Traditional reactors are usually made of ordinary materials with limited corrosion resistance. They are easily corroded by reactants during long-term use, which not only shortens the service life of the equipment, but also may affect product quality due to the mixing of corrosion products into the reaction system. In addition, reactants are easily adhered to the inner wall, making it difficult to clean, causing material residue and waste.

[0004] In traditional systems, raw material feeding and catalyst addition often lack precision, making it difficult to achieve precise ratio control, which not only affects the progress of the reaction and the formation of products, but may also lead to an increase in side reactions and reduce product purity and yield.

[0005] The stirring method in traditional systems is usually relatively simple and cannot be flexibly adjusted according to the reaction process. It may lead to uneven mixing of reaction materials and large differences in local concentration and temperature, thus affecting reaction efficiency and product quality.

[0006] The control of temperature and pressure in traditional systems is not precise and rapid enough, making it difficult to quickly achieve and stably maintain ideal reaction conditions, which may lead to unstable reaction rates, reduced reaction selectivity, and even safety accidents.

[0007] Product separation in traditional systems has low efficiency and accuracy, making it difficult to effectively remove impurities and separate target products, affecting product purity and quality stability.

[0008] Exhaust gas treatment is not effective in traditional systems and cannot fully remove harmful gases, causing significant pollution to the environment.

[0009] In addition, the control method of the traditional system is relatively extensive and relies on manual experience. It is difficult to make precise adjustments in real time according to the reaction situation, resulting in poor production stability and difficulty in ensuring product quality consistency.

[0010] Faced with these problems, the field of pharmaceutical intermediate synthesis urgently needs an innovative synthesis system that can overcome the defects of traditional systems and achieve an efficient, precise, controllable, safe and environmentally friendly synthesis process to meet the increasingly high pharmaceutical quality requirements and environmental protection standards. Summary of the invention

[0011] In order to solve the above technical problems, the present invention provides a pharmaceutical intermediate synthesis system to solve the above problems.

[0012] A pharmaceutical intermediate synthesis system, comprising a reaction kettle, a raw material feeding module, a catalyst adding module, a stirring module, a temperature control module, a pressure regulating module, a product separation module, a tail gas treatment module, an online monitoring module and a control system;

[0013] The raw material feeding module, catalyst adding module, stirring module, temperature control module, pressure regulating module, product separation module, tail gas treatment module and online monitoring module are all connected to the control system;

[0014] The reactor is made of a new type of corrosion-resistant alloy material, and the inner wall has a special anti-stick coating structure.

[0015] Preferably, the raw material feeding module comprises a raw material storage tank and a metering pump, and the raw material storage tank is connected to the reactor via the metering pump;

[0016] The metering pump adopts an intelligent frequency conversion control element.

[0017] Preferably, the catalyst adding module comprises a catalyst storage tank and a quantitative adding device, the catalyst storage tank is connected to the reaction kettle via the quantitative adding device, and the quantitative adding device is equipped with a micro-nano-scale atomizing nozzle structure.

[0018] Preferably, the stirring module comprises a stirring motor and a stirring paddle, wherein the stirring motor is mounted on the top of the reactor, the stirring paddle is located inside the reactor and connected to the stirring motor, and the stirring paddle is designed with a variable blade angle.

[0019] Preferably, the temperature control module comprises a heating device and a cooling device, both of which are connected to the reaction kettle, the heating device adopts a microwave-assisted heating element, and the cooling device adopts a liquid nitrogen spray cooling structure.

[0020] Preferably, the pressure regulating module includes a pressure sensor and a pressure relief valve, the pressure sensor is installed on the reactor, the pressure relief valve is connected to the reactor, the pressure sensor has high precision and fast response characteristics, and the pressure relief valve adopts an electromagnetic pulse control structure.

[0021] Preferably, the product separation module includes a filter and a distillation tower. The filter is installed at the outlet of the reactor, and the distillation tower is connected to the filter. The filter adopts a membrane filtration structure with a self-cleaning function, and a new high-efficiency tower plate structure is provided inside the distillation tower.

[0022] Preferably, the exhaust gas treatment module includes an absorption tower and an activated carbon adsorption device, the absorption tower is connected to the exhaust gas outlet of the reactor, the activated carbon adsorption device is connected to the absorption tower, the absorption tower is filled with independently developed high-efficiency absorbent material, and the activated carbon adsorption device adopts a multi-layer composite activated carbon structure.

[0023] Preferably, the online monitoring module includes a temperature sensor, a pressure sensor, a pH sensor and a concentration sensor, each of which is installed in the reactor and connected to the control system. The sensors are connected to the control system using wireless transmission technology and have functional modules for automatic calibration and fault diagnosis.

[0024] Preferably, the control system includes a controller and a human-computer interaction interface, the controller is connected to each module respectively, the human-computer interaction interface is connected to the controller, the controller adopts an optimization control strategy based on an artificial intelligence algorithm, and the human-computer interaction interface adopts virtual reality technology.

[0025] Compared with the prior art, the present invention has the following beneficial effects:

[0026] 1. The reactor made of new corrosion-resistant alloy material and special anti-stick coating reduces the adhesion and residue of reactants and shortens the cleaning time of the reactor, thereby increasing the effective reaction time. The high-precision raw material feeding module and catalyst adding module ensure the accurate proportion and uniform dispersion of the reaction materials, improve the reaction rate and conversion rate, reduce the occurrence of side reactions, and thus shorten the synthesis cycle. The efficient temperature control module and pressure regulation module can quickly reach and stably maintain the ideal reaction conditions, further accelerating the reaction process.

[0027] 2. Precise feed control and uniform catalyst distribution make the reaction more complete and controllable, reduce the generation of impurities, and improve the purity and yield of the product. The adjustable stirring module ensures the full mixing of the reaction materials, avoids local concentration unevenness and temperature differences, and helps to produce more uniform and high-quality products. The advanced product separation module can more effectively remove impurities and separate target products, significantly improving the purity and quality stability of the product.

[0028] 3. High-precision pressure sensors and fast-response pressure relief valves can accurately monitor and quickly handle abnormal pressure conditions in real time, effectively reducing safety risks caused by pressure out of control.

[0029] 4. The efficient exhaust gas treatment module can remove harmful gases more thoroughly, reduce pollution to the environment, and meet environmental protection requirements.

[0030] 5. The special coating on the inner wall of the reactor reduces the adhesion and waste of reactants, reduces the cost of raw materials, achieves higher reaction efficiency and product yield, and better product quality stability, reduces the generation of waste and defective products, and thus reduces production costs.

[0031] 6. The control system based on artificial intelligence algorithm can automatically optimize the reaction parameters according to real-time data, reduce human operation errors, and improve the stability and consistency of production. The human-computer interaction interface of virtual reality technology provides operators with an intuitive and convenient operation experience, reducing the difficulty of operation and training costs. BRIEF DESCRIPTION OF THE DRAWINGS

[0032] Figure 1 It is a schematic diagram of the system structure of the present invention. DETAILED DESCRIPTION

[0033] The following embodiments of the present invention are described in further detail in conjunction with the accompanying drawings and examples. The following examples are used to illustrate the present invention, but are not intended to limit the scope of the present invention.

[0034] The present invention proposes a pharmaceutical intermediate synthesis system, which aims to solve the problems of low efficiency, poor precision, weak controllability, etc. in the existing pharmaceutical intermediate synthesis process. The various components and working process of the system will be described in detail below.

[0035] The pharmaceutical intermediate synthesis system is mainly composed of a reactor, a raw material feeding module, a catalyst adding module, a stirring module, a temperature control module, a pressure regulating module, a product separation module, an exhaust gas treatment module, an online monitoring module and a control system. Each module works together under the unified coordination of the control system to achieve efficient and accurate synthesis of pharmaceutical intermediates. During operation, the raw materials are accurately fed into the reactor according to a predetermined ratio through the feeding module, the catalyst adding module adds the catalyst quantitatively and timely, the stirring module ensures that the reaction materials are fully mixed, the temperature control module and the pressure regulating module maintain appropriate reaction conditions, the online monitoring module feeds back various parameters in the reaction process in real time, the product separation module separates and purifies the synthetic products, and the exhaust gas treatment module harmlessly treats the generated exhaust gas. The entire process is intelligently controlled by the control system.

[0036] The reactor of this system is made of a new type of corrosion-resistant alloy material, and the inner wall has a special anti-stick coating structure. This new type of corrosion-resistant alloy material is a nickel-molybdenum-tungsten alloy, in which the nickel content is about 60%, the molybdenum content is about 20%, the tungsten content is about 10%, and the rest is a small amount of other alloy elements. Compared with traditional stainless steel materials, the corrosion rate of this alloy in strong acid and strong alkali environments is reduced by more than 80%, which greatly extends the service life of the reactor. The special anti-stick coating structure consists of three layers, the bottom layer is a titanium metal transition layer with a thickness of about 50 microns, the middle layer is a polyetheretherketone (PEEK) coating with a thickness of about 200 microns, and the outermost layer is a diamond-like carbon (DLC) coating with a thickness of about 50 microns. This coating structure reduces the adhesion rate of reactants on the inner wall of the reactor by more than 95%, greatly reducing product residue and cleaning difficulty. The following is a comparison of the corrosion resistance of reactor materials:

[0037] Material Corrosion rate (mm / year) Traditional stainless steel 0.5-1.0 New corrosion-resistant alloy of the present invention 0.05-0.1

[0038] The raw material feeding module includes multiple raw material storage tanks and high-precision metering pumps. The raw material storage tanks store different reaction raw materials, such as chemical substances A, B, C, etc. The metering pump adopts intelligent frequency conversion control technology, which can accurately adjust the feeding speed according to the instructions of the control system. Taking the synthesis of a specific pharmaceutical intermediate as an example, the reaction requires raw materials A and B to be fed in a molar ratio of 2:1. Due to the lack of precision in traditional feeding methods, the actual feeding ratio may fluctuate between 1.8:1 and 2.2:1, resulting in unstable product purity. The metering pump of this system has an accuracy of up to ±0.5%, which can stably control the feeding ratio between 1.98:1 and 2.02:1, significantly improving the purity and consistency of the product. The following is a comparison of feeding accuracy data:

[0039] Feeding method Feed ratio fluctuation range Traditional feeding method ±10％ Feed module of the present invention ±1％

[0040] The catalyst addition module includes a catalyst storage tank and an advanced quantitative addition device. The quantitative addition device is equipped with a micro-nano-scale atomizing nozzle, which can evenly disperse the catalyst into the reaction system. For example, when performing a certain catalytic reaction, the traditional dripping method may cause the local concentration of the catalyst to be too high or too low, affecting the reaction efficiency and selectivity. The atomizing nozzle of this system can atomize the catalyst into droplets with an average particle size of about 500 nanometers, which are evenly distributed in the reactor, shortening the reaction time by 30% and increasing the product yield by 15%. The following is the comparative data of reaction time and product yield:

[0041] Add method Response time (hours) Product yield (%) Traditional drip 8 75 The present invention adds atomization 5.6 86.25

[0042] The stirring module consists of a stirring motor and a stirring paddle with a variable blade angle. The stirring motor can provide different speeds, and the blade angle of the stirring paddle can be adjusted according to the reaction process. In the early stage of the reaction, strong stirring is required to quickly mix the raw materials. At this time, the blade angle of the stirring paddle is adjusted to 60 degrees and the speed is set to 500 rpm. As the reaction proceeds, the blade angle of the stirring paddle gradually decreases to 30 degrees and the speed is reduced to 200 rpm, which can ensure that the reaction is fully carried out and reduce energy consumption. The following is a comparison of energy consumption under different stirring conditions:

[0043]

[0044] The temperature control module consists of an efficient heating device and a rapid cooling device. The heating device uses microwave-assisted heating technology, which can evenly increase the temperature in the reactor in a short time. The cooling device uses a liquid nitrogen spray cooling structure, which can quickly reduce the reaction temperature. In a reaction that needs to be quickly heated to 150°C, the traditional electric heating method takes about 30 minutes to heat up, and the temperature distribution is uneven. The microwave-assisted heating of this system can reach the target temperature in just 10 minutes, and the temperature deviation is less than ±2°C. In the cooling stage, the traditional water cooling method takes 60 minutes to cool the reactor from 150°C to room temperature, while liquid nitrogen spray cooling only takes 20 minutes. The following is a comparison of the heating time and cooling time:

[0045]

[0046] The pressure regulating module includes a high-precision pressure sensor and a fast-response pressure relief valve. The pressure sensor can accurately monitor the pressure changes in the reactor in real time. The pressure relief valve adopts electromagnetic pulse control and can quickly release pressure in an emergency. In high-pressure reactions, the measurement accuracy of traditional pressure sensors is usually ±0.5MPa, and the response time is about 1 second. The pressure sensor accuracy of this system can reach ±0.1MPa, and the response time is less than 0.1 second. When the pressure exceeds the set safety value, the opening time of the traditional pressure relief valve is about 2 seconds, while the opening time of the electromagnetic pulse pressure relief valve of the present invention is only 0.5 seconds, which greatly improves the safety of the reaction.

[0047] The product separation module consists of a high-precision filter and a high-efficiency distillation tower. The filter adopts a membrane filtration structure with a self-cleaning function, which can effectively remove solid impurities. A new high-efficiency tower plate is installed inside the distillation tower to improve the separation efficiency. When separating a certain product, the filtration accuracy of the traditional filter is about 10 microns and the filtration efficiency is 80%. The filter of this system has a filtration accuracy of up to 1 micron and a filtration efficiency of more than 98%. The new high-efficiency tower plate increases the separation efficiency of the distillation tower by 20%, and the product purity is increased from 95% to more than 98%. The following is a comparison of filtration accuracy and separation efficiency:

[0048]

[0049]

[0050] The tail gas treatment module includes an absorption tower and an activated carbon adsorption device. The absorption tower is filled with high-efficiency absorbents, which can effectively absorb harmful gases. The activated carbon adsorption device adopts a multi-layer composite activated carbon structure to further remove residual harmful substances. According to tests, the removal rate of harmful gases by traditional tail gas treatment methods is about 80%, while the removal rate of harmful gases by the tail gas treatment module of this system reaches more than 98%, greatly reducing pollution to the environment.

[0051] The online monitoring module includes multiple high-precision sensors, such as temperature sensors, pressure sensors, pH sensors, and concentration sensors, etc. These sensors can collect various parameters in the reactor in real time and send the data to the control system through wireless transmission technology. The measurement accuracy and response time of the sensors are better than those of traditional monitoring equipment, and can provide the control system with more accurate and timely information to precisely control the reaction process.

[0052] The control system adopts an optimization control strategy based on artificial intelligence algorithms, and can adjust the working parameters of each module in real time according to the data fed back by the online monitoring module to realize intelligent control of the synthesis process. The human-computer interaction interface adopts virtual reality technology to provide operators with an intuitive and convenient operation experience. Through the comparison of actual operation data, the control system of the present invention can improve the stability of the reaction by more than 30%, and the consistency of product quality is significantly improved.

[0053] The reactor made of new corrosion-resistant alloy material and special anti-stick coating reduces the adhesion and residue of reactants and shortens the cleaning time of the reactor, thereby increasing the effective reaction time. The high-precision raw material feeding module and catalyst adding module ensure the accurate proportion and uniform dispersion of the reaction materials, improve the reaction rate and conversion rate, reduce the occurrence of side reactions, and thus shorten the synthesis cycle. The efficient temperature control module and pressure regulation module can quickly reach and stably maintain the ideal reaction conditions, further accelerating the reaction process.

[0054] Precise feed control and uniform catalyst distribution make the reaction more complete and controllable, reduce the generation of impurities, and improve the purity and yield of the product. The adjustable stirring module ensures the full mixing of the reaction materials, avoids local concentration unevenness and temperature differences, and helps to produce more uniform and high-quality products. The advanced product separation module can more effectively remove impurities and separate target products, significantly improving the purity and quality stability of the product.

[0055] High-precision pressure sensors and fast-response pressure relief valves can accurately monitor and quickly handle abnormal pressure conditions in real time, effectively reducing the safety risks caused by pressure runaway. The optimized temperature control module reduces the dangers caused by temperature runaway and ensures the safe and smooth progress of the reaction process.

[0056] The efficient exhaust gas treatment module can remove harmful gases more thoroughly, reduce pollution to the environment, and meet environmental protection requirements. The special coating on the inner wall of the reactor reduces the adhesion and waste of reactants, reduces raw material costs, higher reaction efficiency and product yield, and better product quality stability, reducing the generation of waste and defective products, thereby reducing production costs. Optimized energy utilization and reduced cleaning time reduce energy consumption and labor costs. The control system based on artificial intelligence algorithms can automatically optimize reaction parameters according to real-time data, reduce human operating errors, and improve production stability and consistency. The human-computer interaction interface of virtual reality technology provides operators with an intuitive and convenient operating experience, reducing operating difficulty and training costs.

[0057] The embodiments of the present invention are given for the purpose of illustration and description, and are not intended to be exhaustive or to limit the invention to the disclosed forms. Many modifications and variations will be apparent to those of ordinary skill in the art. The embodiments are selected and described in order to better illustrate the principles and practical applications of the present invention and to enable those of ordinary skill in the art to understand the present invention and thereby design various embodiments with various modifications suitable for specific uses.

Claims

1. A pharmaceutical intermediate synthesis system, characterized in that: It includes a reactor, a raw material feeding module, a catalyst adding module, a stirring module, a temperature control module, a pressure regulating module, a product separation module, a tail gas treatment module, an online monitoring module and a control system; The raw material feeding module, catalyst adding module, stirring module, temperature control module, pressure regulating module, product separation module, tail gas treatment module and online monitoring module are all connected to the control system; Wherein, the reactor is made of corrosion-resistant alloy material, and the inner wall has an anti-stick coating.

2. A pharmaceutical intermediate synthesis system as claimed in claim 1, characterized in that: The raw material feeding module comprises a raw material storage tank and a metering pump, and the raw material storage tank is connected to the reactor via the metering pump.

3. A pharmaceutical intermediate synthesis system as claimed in claim 1, characterized in that: The catalyst adding module comprises a catalyst storage tank and a quantitative adding device, the catalyst storage tank is connected to the reaction kettle via the quantitative adding device, and the quantitative adding device is equipped with a micro-nano-scale atomizing nozzle structure.

4. A pharmaceutical intermediate synthesis system as claimed in claim 1, characterized in that: The stirring module comprises a stirring motor and a stirring paddle, wherein the stirring motor is mounted on the top of the reaction kettle, and the stirring paddle is located inside the reaction kettle and connected to the stirring motor.

5. A pharmaceutical intermediate synthesis system as claimed in claim 1, characterized in that: The temperature control module comprises a heating device and a cooling device, both of which are connected to the reaction kettle. The heating device adopts a microwave-assisted heating element, and the cooling device adopts a liquid nitrogen spray cooling structure.

6. A pharmaceutical intermediate synthesis system as claimed in claim 1, characterized in that: The pressure regulating module comprises a pressure sensor and a pressure relief valve. The pressure sensor is installed on the reactor. The pressure relief valve is connected to the reactor. The pressure relief valve adopts an electromagnetic pulse control structure.

7. A pharmaceutical intermediate synthesis system as claimed in claim 1, characterized in that: The product separation module comprises a filter and a distillation tower. The filter is installed at the outlet of the reactor, and the distillation tower is connected to the filter.

8. A pharmaceutical intermediate synthesis system as claimed in claim 1, characterized in that: The tail gas treatment module comprises an absorption tower and an activated carbon adsorption device. The absorption tower is connected to the tail gas outlet of the reactor, and the activated carbon adsorption device is connected to the absorption tower.

9. A pharmaceutical intermediate synthesis system as claimed in claim 1, characterized in that: The online monitoring module includes a temperature sensor, a pressure sensor, a pH sensor and a concentration sensor. Each sensor is installed in the reactor and connected to the control system. The sensors are connected to the control system using wireless transmission technology and have functional modules for automatic calibration and fault diagnosis.

10. A pharmaceutical intermediate synthesis system as claimed in claim 1, characterized in that: The control system comprises a controller and a human-machine interaction interface. The controller is connected to each module respectively, and the human-machine interaction interface is connected to the controller.

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