Reconfigurable technological complex for implementation of organic synthesis platforms and method for its use

Abstract

FIELD: chemical engineering.SUBSTANCE: invention can be used to implement organic synthesis processes on a pilot and industrial scale. The reconfigurable technological complex contains a common assembly circuit and a set of replaceable technological modules, made in individual metal frames as complete functional units. The replaceable modules are organized into organic synthesis technology platforms in the form of pre-defined platform configurations, each of which corresponds to a specific class of organic synthesis reactions. The complex enables the replacement, connection, and addition of modules during the transition between platform configurations without the need to manufacture a new complex. The invention also concerns a method for using the complex and includes selecting a platform configuration for the target organic synthesis product, assembling the complex from modules of the selected platform, carrying out the process and subsequent reconfiguration of the complex.EFFECT: expanding the technological capabilities of the complex and reducing the time required for production restructuring.11 cl, 5 ex

Description

[0001] The invention relates to industrial and pilot-industrial chemical-engineering equipment, namely to reconfigurable technological complexes for the implementation of organic synthesis processes and to methods for organizing such processes using the platform principle of equipment arrangement, is intended for the production of target products of basic and fine chemistry, petrochemistry, pharmaceutical intermediates, fuel additives, monomers and intermediates for polymers, surfactants, solvents, plasticizers and other products obtained on the said platforms and can be applicable to technological platforms of organic synthesis, including, in particular: oxo synthesis (hydroformylation, carbonylation, cyclocarbonylation, reductive amination), hydrogenation and dehydrogenation, oxidation, alkylation and acylation, sulfation, sulfonation and nitration, hydrolysis, hydration, dehydration, esterification, amidation, ammonolysis,halogenation, oligomerization of alkenes, phosgenation, diene synthesis and biocatalysis.,

[0002] A reconfigurable system for multi-stage chemical synthesis is known from the prior art according to the patent family US11185839B2 (priority date 02.05.2017. IPC B01J 8 / 00, B01J 14 / 00, B01J 19 / 00, B01J 19 / 24, B01L 3 / 00. Applicants: Massachusetts Institute of Technology), comprising a fluid distributor with several compartments having standardized fluid connections, and replaceable modules designed with the possibility of installation in any compartment of the distributor in any order. Each module implements one or more process operations (reaction, separation, mixing); the modules are connected in series via fluid lines, and sensor signals are transmitted via electrical interfaces of the distributor; wherein the system ensures the implementation of a large number of classes of reactions on one hardware platform by reinstalling the modules.

[0003] The disadvantages of the declared reconfigurable system are:

[0004] • the solution is focused on fluid (micro- and meso-fluid) implementation and laboratory-research scale and does not disclose the pilot-industrial complex with modules in individual metal frames as autonomous technological units;

[0005] • the implementation of a full set of platforms for organic synthesis for industrial applications (oxosynthesis, oxidation, halogenation, phosgenation, nitration, biocatalysis, etc.), requiring specific hardware designs and coolant circuits, is not disclosed;

[0006] • the distributed electrical and automated control system architecture with its own switchgear and automated process control system cabinets for each module, united by a common control system using industrial protocols, is not disclosed;

[0007] • the method for selecting and assembling a platform configuration for a class of reactions or a specific target product is not disclosed.

[0008] A modular structural system is known from the prior art according to the patent family CA3092669A1 / RU2758296C1 (priority date 02.03.2018, IPC E04B 1 / 00, E04B 1 / 343, E04B 1 / 348, E04H 1 / 00. Applicant: Modular Plant Solutions LLC.), comprising at least two modules, each of which has its own frame structure and the equipment of a process plant placed therein. The modules are designed with the possibility of individual transportation to the assembly site, are pre-equipped with pipelines, electrical wiring and control and measuring means and are connected to each other by means of corner connecting elements to form a modular process plant. In particular embodiments, the known system can be used to form a chemical production plant, including plants for the production of methanol, gasoline, dimethyl ether or a plant for processing gas into liquid products.

[0009] The disadvantages of the declared modular structural system are:

[0010] • the solution is aimed primarily at the supporting and transportable structure of the modular installation and does not disclose the platform organization of organic synthesis processes;

[0011] • pre-assembled platform configurations of modules for reaction classes (oxosynthesis, hydrogenation, oxidation, alkylation, nitration, etc.) are not disclosed;

[0012] • The method for rebuilding the process flow diagram for the target product by selecting a platform configuration from a predetermined set is not disclosed.

[0013] Also known from the prior art is a configuration of multi-purpose chemical production equipment with the ability to switch between several processes on one set of devices and a method for operating it according to patent JPH06114259 (priority date 05.10.1992, IPC B01J 19 / 00. Applicant: TSURUTA HIDEMASA), which discloses an installation consisting of individual functional process units connected to each other to form a single process flow diagram.

[0014] The known system comprises functional sections designed to perform various stages of the technological process, including sections for feeding and increasing the working fluid pressure, reaction sections, heat exchange sections, and sections for separating the process products. Individual process units are connected by pipelines and shut-off and control valves to form a modular process unit suitable for chemical engineering processes.

[0015] The disadvantages of the declared configuration are:

[0016] • the solution is focused on operational switching between a limited set of pre-designed processes within a single technological unit and does not expose the hardware complex of autonomous modules in individual frames;

[0017] • the platform organization of organic synthesis processes with pre-assembled configurations for reaction classes is not disclosed;

[0018] • The distributed control system architecture with its own cabinets for each module is not disclosed.

[0019] A multi-level modular structure for chemical production is known from the prior art according to US Patent 5,474,411 A (priority date 21.05.1993. IPC E04H 5 / 00, B01J 19 / 00, Applicant: Nukem GmbH). This technical solution discloses a modular design of a chemical plant containing a set of structural segments made in the form of spatial modules placed adjacent to each other and forming a multi-level production structure. Process equipment, pipelines, valves, utilities and process spaces necessary for carrying out chemical processes, including pharmaceutical production processes, are located within these segments. The structural segments are equipped with passages and process access zones providing for servicing of the equipment located therein.

[0020] The disadvantages of this multi-level modular structure are:

[0021] • the solution is aimed at the construction and assembly organization of modular production and does not disclose the technological reconfiguration based on the principle of an organic synthesis platform;

[0022] • functionally different technological modules with their own coolant circuits and control cabinets are not disclosed;

[0023] • The method for selecting a platform configuration for a reaction class is not disclosed.

[0024] The applicant was previously granted Russian Federation Patent No. 2833417 for a modular pilot facility for studying chemical engineering processes and a method for using it. This technical solution pertains to pilot chemical engineering facilities and describes the principle of constructing a research facility from interchangeable functional modules housed in individual frames and connected by a distributed control system.

[0025] This well-known solution enables the configuration of a research facility to be modified by adding, replacing, or removing individual functional modules depending on the parameters of the process being studied. It also reveals the general principles of modular design for a pilot facility, including reactor, heat exchange, separation, and other process modules.

[0026] The technical solution claimed in this application develops and concretizes this principle toward the creation of a production-oriented modular system for implementing organic synthesis processes. Unlike the previously patented solution, the claimed technical solution involves the formation of technological platforms, each of which represents a predetermined set of functional modules, pre-configured to perform a specific class of organic synthesis reactions or to produce a target chemical product.

[0027] A significant distinction of the proposed solution is that the modular system is designed to allow selection, connection, and switching between various platform configurations depending on the required synthesis process route, process parameters, reagent composition, and target product. Each process platform can contain a pre-agreed set of reactor, heat exchange, separation, dosing, compressor, and control modules, enabling the corresponding class of chemical transformations.

[0028] Furthermore, the proposed solution is aimed not only at conducting pilot-scale research, but also at creating a scalable production platform for the rapid adaptation of the process flow diagram to various organic synthesis processes without completely redesigning the installation.

[0029] Thus, the claimed technical solution differs from our own previous solution by a new principle of platform organization of a modular installation, which provides for the formation and switching of predetermined technological configurations for various organic synthesis processes, which ensures the expansion of the functional capabilities of the system and an increase in its adaptability to industrial application.

[0030] Preliminarily, the closest in technical essence to the claimed solution is recognized to be the analogue according to patent US 11185839 B2, which discloses a reconfigurable system for multi-stage chemical synthesis.

[0031] The task that the claimed technical solution is aimed at solving is the creation of a reconfigurable technological complex and a method for its use, ensuring the implementation of many classes of organic synthesis processes on a single hardware base by selecting, connecting and using pre-defined platform configurations of technological modules for obtaining the target product without the need to design and manufacture a new technological installation as a whole.

[0032] The technical result achieved by implementing the claimed invention consists in expanding the technological capabilities of a single hardware complex to implement multiple classes of organic synthesis processes, reducing the time and volume of work on restructuring the process flow diagram when switching from one target product to another, increasing the reproducibility of the assembly of the process complex, reducing the need to stop the entire complex during maintenance, replacement or modernization of individual modules, ensuring a unified control architecture while maintaining the autonomy of electrical equipment and automation equipment of individual modules, as well as increasing the adaptability of the complex to processes that impose different requirements on reactor equipment, heat exchange, feedstock supply, phase separation, pressure regulation and flow rate of process media.

[0033] The specified technical result is achieved due to the fact that the technological complex is made according to the modular principle and contains a common assembly circuit designed to accommodate replaceable technological modules made in individual frames in the form of structurally and functionally complete units containing technological equipment, piping, fittings, control and measuring instruments, power supply means and automated control elements, while the modules are made with the possibility of selective connection, replacement, exclusion and addition to the composition of the complex by means of unified pipeline, electrical and information interfaces.

[0034] Expansion of the complex's technological capabilities is achieved through the creation of predefined platform configurations of modules, each designed to implement a specific class of organic synthesis processes, including oxosynthesis, hydrogenation, dehydrogenation, oxidation, alkylation, acylation, sulfation, sulfonation, nitration, hydrolysis, hydration, dehydration, esterification, amidation, ammonolysis, halogenation, alkene oligomerization, phosgenation, diene synthesis, and biocatalysis. The ability to select the required platform configuration enables the implementation of various technological processes on a single hardware base without completely redesigning the complex.

[0035] The reduction in the time and volume of work on restructuring production is achieved by the fact that the transition between different technological processes is carried out by replacing, connecting or reconfiguring pre-prepared platform sets of modules, previously adapted to a specific technological route of synthesis and the target product, without the need to manufacture a new installation or significantly change the basic infrastructure of the complex.

[0036] Increasing the reproducibility of the assembly of the process flow diagram is achieved by producing modules in individual frames with standardized connecting elements and unified connection interfaces, ensuring a standardized layout of process units and reducing the likelihood of errors during repeated assembly and reconfiguration of the complex.

[0037] Reducing the need to stop the entire complex for maintenance, replacement or modernization of individual modules is achieved by the autonomy of the process modules and the ability to locally disconnect them from the general process circuit through detachable connections and independent connection lines, which allows for the replacement or maintenance of individual functional units without a complete shutdown of the complex.

[0038] Ensuring a unified control architecture is achieved by the fact that the control system of the complex is built on the basis of distributed logical controllers connected to the general control system via standard data transmission protocols, while each module can contain its own VRU cabinet and APCS, providing local control of the corresponding module while maintaining integration into the general automated control system of the complex.

[0039] Increased adaptability of the complex to various organic synthesis processes is achieved through the ability to form various combinations of reactor, heat exchange, separation, dosing, compressor and control modules, differing in design, operating principle and process parameters, which makes it possible to implement processes with different requirements for reaction modes, heat and mass transfer, phase separation, reagent supply and regulation of process parameters.

[0040] The claimed technical solution is disclosed as a group of inventions united by a single inventive concept: a reconfigurable technological complex for the implementation of organic synthesis platforms and a method for its use.

[0041] In a particular embodiment of the claimed invention, the reconfigurable technological complex contains a common assembly circuit and a set of replaceable technological modules, each of which is made in an individual metal frame in the form of a structurally and functionally complete unit containing technological equipment, piping, shut-off and control valves, control and measuring instruments, as well as its own cabinets of the main switchgear and automated process control system or means of connection to the distributed control system of the complex.

[0042] The common installation circuit allows for the placement, connection, replacement, disconnection, and reconfiguration of replaceable process modules via standardized mechanical, piping, electrical, and information interfaces. Each module is designed to operate independently within the complex and subsequently integrate into the overall process and control infrastructure.

[0043] Replaceable process modules can be selected from a group that includes reactor modules, heat exchange modules, capacity modules, separation modules, dynamic feedstock supply modules, compressor modules, process fluid pressure and flow control modules, special media supply and preparation modules, product neutralization and decontamination modules, catalytic packaging and catalyst regeneration modules, and biocatalytic unit modules.

[0044] Reactor modules are available in tubular, bubble, tube-in-tube, tank-and-stirrer, jacketed, and shell-and-tube designs. The ability to use reactor modules of various design types allows the system to be adapted to organic synthesis processes with different heat and mass transfer conditions, mixing modes, reactant residence times, and reaction parameters.

[0045] Heat exchange modules may include a coolant circulation module, an evaporating coolant circulation module, a thermostatting module, a shell-and-tube heat exchanger module, a shell-and-wall heat exchanger module, and an air cooling module. These modules ensure the maintenance of the required temperature conditions for organic synthesis processes and the ability to modify the heat exchange scheme depending on the process platform parameters.

[0046] Capacitance modules can be configured as low- or high-pressure modules for gas, liquid, and gas-liquid media. Modules can be equipped with controls for temperature, pressure, level, and mass of the process medium.

[0047] Separation modules can be designed as high-pressure separation modules, low-pressure separation modules and three-phase separation modules for separating gas, liquid and gas-liquid flows.

[0048] Dynamic feed modules can include plunger, membrane, gear and syringe pump modules, providing metered supply of reagents with specified flow and pressure parameters.

[0049] Compressor modules can be made in piston or membrane design and are designed for supplying, circulating and compressing gaseous media.

[0050] Special media supply and preparation modules can handle synthesis gas, hydrogen, ammonia, oxygen, chlorine and other halogens, phosgene, oleum, sulfuric anhydride, nitric acid and sulfuric acid, depending on the selected technology platform and the organic synthesis process being implemented.

[0051] Modules for neutralization and decontamination of products are designed to process side and waste streams generated during chemical engineering processes.

[0052] Catalytic packaging and catalyst regeneration modules provide placement, replacement, recovery and reuse of catalytic systems used in the process.

[0053] Biocatalytic unit modules are designed to carry out biocatalytic processes using enzymatic, microbiological or other biocatalytic systems.

[0054] Replaceable process modules are organized into organic synthesis process platforms. A process platform is defined as a predefined and pre-assembled subset of replaceable process modules with a predetermined connection scheme, enabling the implementation of a specific class of organic synthesis processes within a single assembly circuit.

[0055] The technology platforms may include an oxo synthesis platform, a hydrogenation and dehydrogenation platform, an oxidation platform, an alkylation and acylation platform, a sulfation, sulfonation and nitration platform, a hydrolysis, hydration, dehydration, esterification and amidation platform, a halogenation platform, an alkene oligomerization platform, a phosgenation platform, a diene synthesis platform, and a biocatalysis platform.

[0056] The complex control system can be built on distributed programmable logic controllers (DPLCs) with connection to the overall control system via standard industrial data transfer protocols, including ModbusRTU, ModbusTCP, OPCUA, Profinet, or equivalent data transfer protocols. Each module can have its own input distribution and process control system (APCS) cabinet or be designed to connect to the cabinets of adjacent modules and the overall complex cabinet.

[0057] In general industrial applications, the switchgear and automated process control system cabinets can be located outside the hazardous area. Alternatively, explosion-proof equipment may be provided in accordance with the requirements of TR CU 012 / 2011.

[0058] The method of using a reconfigurable technological complex for carrying out organic synthesis processes includes determining the target product of organic synthesis and the corresponding class of chemical reactions, selecting the corresponding technological platform from among predetermined platform configurations, equipping the general assembly circuit with replaceable technological modules of the selected platform, connecting said modules to the general control system of the complex, carrying out the technological process with the registration of operating parameters, material and energy balances, as well as data on the properties of the resulting product, wherein, when switching to obtaining another target product, one or more technological modules are replaced, disconnected, connected, or supplemented in accordance with a different platform configuration without manufacturing a new technological complex as a whole.

[0059] In a particular embodiment of the method, after determining the target product, the required class of organic synthesis reactions is identified, on the basis of which the corresponding technological platform is selected, which is a predetermined and pre-assembled subset of technological modules with a given scheme for their connection, ensuring the implementation of the corresponding organic synthesis process.

[0060] The overall installation circuit is assembled by installing and connecting modules of the selected platform via standardized mechanical, piping, electrical, and information interfaces. After connecting the modules, their local control systems are integrated into the overall distributed control system of the complex.

[0061] The organic synthesis process is carried out in a selected platform configuration with control of temperature, pressure, flow rate, flow composition, heat exchange parameters, operating modes of reactor units and phase separation parameters, while data on the progress of the process, material and energy balance, as well as the characteristics of the target product are recorded by means of the automated control system of the complex.

[0062] When switching to the production of another target product, individual process modules are replaced, excluded, connected, or supplemented in accordance with a different platform configuration corresponding to the required class of organic synthesis reactions, without changing the basic design of the complex and without manufacturing a new process unit.

[0063] The essential distinguishing features of the claimed technical solution are that the replaceable technological modules are organized into technological platforms of organic synthesis, each of which corresponds to a specific class of chemical reactions and represents a predetermined platform configuration of modules with a given scheme for their connection.

[0064] Furthermore, a distinctive feature is the presence of a set of pre-defined platform configurations designed to implement the processes of oxosynthesis, hydrogenation and dehydrogenation, oxidation, alkylation and acylation, sulfation, sulfonation and nitration, hydrolysis, hydration, dehydration, esterification and amidation, halogenation, oligomerization of alkenes, phosgenation, diene synthesis and biocatalysis.

[0065] An additional distinguishing feature is the implementation of each process module in an individual metal frame with its own cabinets for the main switchgear and automated process control system, or with means for connecting to the distributed control system of the complex, ensuring the autonomous operation of the modules while maintaining integration into a single control system.

[0066] Also a distinctive feature is the presence in the complex of specialized modules for the supply and preparation of process media, including synthesis gas, hydrogen, ammonia, oxygen, chlorine and other halogens, phosgene, oleum, sulfuric anhydride, nitric acid and sulfuric acid, as well as modules for neutralization and detoxification of products, ensuring the adaptation of the complex to various technological platforms of organic synthesis.

[0067] An essential distinguishing feature of the claimed solution is also the ability to select a platform configuration for the target product and switch between different platform configurations without manufacturing a new complex as a whole, as well as communication between distributed module controllers and the general control system via standard industrial data transfer protocols, including ModbusRTU, ModbusTCP, OPCUA, Profinet or equivalent protocols.

[0068] The reconfigurable technological complex is designed to implement multiple classes of organic synthesis processes on a single hardware base and ensures the implementation of organic synthesis processes on a pilot-industrial and industrial scale, the rapid restructuring of the technological configuration when switching from one target product to another, as well as the acquisition of technological, material, energy and operational data used in the design of industrial production.

[0069] The complex is designed on a modular principle and contains a common assembly circuit designed to accommodate replaceable process modules. The specific composition of the modules is determined by the selected organic synthesis technology platform and the nature of the process being implemented. When switching to a different technology platform, some modules are dismantled and replaced with modules corresponding to the new platform configuration, while the unchangeable modules providing common functions remain within the complex.

[0070] Unchangeable modules may include air and nitrogen supply modules, water treatment modules, modules for neutralization and disposal of process flows, as well as modules of the general control system of the complex.

[0071] Each process module is made in an individual metal frame as a structurally and functionally complete unit and contains the corresponding process equipment, piping, shut-off and control and safety valves, control and measuring instruments and means of connection to the general control system of the complex.

[0072] Modules are connected to a common assembly circuit using standardized connection elements, including flanged pipe connections and quick-release electrical and signal connections, ensuring reproducible assembly, reducing installation and disassembly time, and reducing the likelihood of errors when forming various platform configurations.

[0073] Each module can contain its own control panel and process control system cabinet, providing power to the module's equipment, collecting signals from control and measuring instruments, controlling actuators, and transmitting data to the complex's overall control system. Communication between the modules' local control systems and the overall control system is accomplished via standard industrial data transmission protocols, including ModbusRTU, ModbusTCP, OPCUA, Profinet, or equivalent data transmission protocols.

[0074] In the general industrial design, the switchgear and automated process control system cabinets can be located outside the hazardous area. Another design option provides explosion-proof equipment in accordance with the requirements of TR CU 012 / 2011.

[0075] The use of a modular design principle for the complex and pre-defined platform configurations makes it possible to implement various classes of organic synthesis processes on a single hardware base without constructing a new installation as a whole, and also ensures a reduction in the time required to redesign the process flow diagram, an increase in the reproducibility of the assembly, and an increase in the adaptability of the complex to various technological processes.

[0076] This reconfigurable process complex is designed to implement multiple classes of organic synthesis reactions on a single hardware base. The complex enables the implementation of specific platform configurations for specific reaction classes, reconfiguration when switching to a different target product, pilot-scale and industrial-scale processes, and the collection of initial data for industrial plant design.

[0077] The complex contains a common assembly circuit housing replaceable process modules. The specific composition of the modules is selected depending on the target organic synthesis platform. When switching to a different platform, some modules are dismantled and replaced with modules corresponding to the new platform configuration; non-changeable modules (typically air and nitrogen supply modules, water treatment, neutralization, and the general control system) are retained.

[0078] Each module is housed in an individual metal frame as a complete functional unit and contains the appropriate equipment, shut-off and control valves, safety valves, pipelines, instrumentation, and connections to the overall control system. Standardized flange connections and quick-release connections for electrical and signal lines ensure reproducible assembly of platform configurations.

[0079] The main switchgear cabinet and the process control system cabinet of each module provide power supply, instrumentation signal collection, actuator control, and communication with the overall control system via standard industrial data transfer protocols (ModbusRTU, ModbusTCP, OPCUA, Profinet, or equivalent). For general-purpose industrial applications, cabinets are located outside the hazardous area; if necessary, a version compliant with TR CU 012 / 2011 is available.

[0080] Oxosynthesis platform

[0081] The platform is designed to implement hydroformylation, carbonylation, cyclocarbonylation and reductive amination reactions. The platform is used to obtain, in particular, aldehydes and alcohols from alkenes and synthesis gas, carboxylic acids, esters and amides from alkenes, carbon monoxide and the corresponding nucleophiles, cyclic ketones from dienes, primary and secondary amines and α-amino acids from carbonyl compounds and ammonia. The platform configuration contains: modules for feeding and preparing synthesis gas and hydrogen; dynamic modules for feeding liquid feedstock; compressor module; reactor module (tubular, bubbling or tank design depending on the reaction subclass); heat exchange heating and cooling modules; pressure control modules; high and low pressure separation modules; product tank modules.The target products include isononyl and isodecyl alcohols, propionic and butyric acids, propyl propionate, pentyl propionate, adipic acid, hexamethylenediamine, aliphatic alcohols C3-C9, aliphatic amines, phenylpropionic acid, ibuprofen and other products of the corresponding series.

[0082] Hydrogenation and Dehydrogenation Platform

[0083] The platform is designed for the catalytic hydrogenation of alkenes and alkynes, aromatic compounds, carbonyl compounds, nitriles and nitro groups, as well as the catalytic dehydrogenation of alkanes, alcohols, cyclohexane structures and amines. The platform configuration includes: hydrogen supply and preparation modules; dynamic liquid and gaseous feedstock supply modules; a reactor module (tubular with a fixed catalyst bed or tank with a stirrer, depending on the subclass); heat exchange heating and cooling modules; pressure control modules; high and low pressure separation modules; product tank modules. Target products include toluenediamine, hexamethylenediamine, styrene, propylene, isobutylene, benzyl alcohol, acetone, butanediol-1,4, cyclohexane, cyclohexanone, fatty alcohols and amines, sorbitol, cyclohexylamine, aniline and other products of the corresponding series.

[0084] Oxidation Platform

[0085] The platform is designed to implement catalytic oxidation reactions of alkanes, alkenes, alcohols, aldehydes, aromatic compounds and heteroatomic compounds using molecular oxygen, air or other oxidizing agents. The platform configuration contains: oxidizer supply and preparation modules (compressor or blower module); dynamic liquid feedstock supply modules; reactor module (bubble, tubular or shell-and-tube depending on the subclass); heat exchange modules providing heat removal from the exothermic reaction; pressure and flow control modules; separation modules; product capacity modules; neutralization and decontamination modules.The target products include terephthalic acid, epichlorohydrin, diglycidyl ethers, ethylene oxide, monoethylene glycol, propylene oxide, propylene glycol, benzoic acid, dimethyl disulfide, pyromellitic and benzophenone tetracarbonyl dianhydrides, hydroquinone, benzoquinone and other products of the corresponding series.

[0086] Alkylation and Acylation Platform

[0087] The platform is designed to implement alkylation reactions at carbon, nitrogen, oxygen and sulfur atoms, as well as acylation of arenes and other substrates. The platform configuration contains: feedstock feeding and preparation modules (including haloalkanes, alcohols, carbonyl compounds, acylating agents); dynamic liquid feedstock feeding modules; a reactor module (a tank with a stirrer and a jacket or a tubular one, depending on the subclass); heat exchange modules; pressure control modules; separation modules; tank modules; neutralization modules. Target products include ethylbenzene, cumene, linear alkylbenzenes, dodecylbenzene, methyl tert-butyl ether, benzophenone, acetophenone, 4-methylacetophenone and other products of the corresponding series.

[0088] Sulfation, Sulfonation and Nitration Platform

[0089] The platform is designed to implement reactions of sulfation of alcohols and alkenes, sulfonation of arenes and alkenes, sulfochlorination, as well as nitration of arenes and alkanes. The platform configuration includes: feed modules for sulfuric acid, oleum, sulfuric anhydride, chlorosulfonic and nitric acids in an appropriate corrosion-resistant design; dynamic feed modules; a reactor module (a tank with a stirrer and a jacket or a tubular one with intensive heat removal); heat exchange modules; pressure control modules; separation modules; tank modules; modules for neutralization and detoxification of acidic wastewater. The target products include alkylbenzenesulfonates, alkylsulfonates, nitrobenzene, nitrochlorobenzenes, nitrotoluenes, nitronaphthalenes, nitroalkanes, p-toluenesulfonic and benzenesulfonic acids and other products of the corresponding series.

[0090] Hydrolysis, Hydration, Dehydration, Esterification, and Amidation Platform

[0091] The platform is designed to implement the reactions of hydrolysis of esters, amides, haloalkanes and nitriles; hydration of alkenes and alkynes; dehydration of alcohols, amides and carboxylic acids; esterification of carboxylic acids with alcohols; amidation of carboxylic acids, their acid chlorides and esters with amines and ammonia. The platform configuration contains: modules for feeding and preparing water and amine / amide reagents; dynamic feeding modules; reactor module (capacitive with a stirrer and jacket or tubular); heat exchange modules; pressure control modules; separation modules; rectification units if necessary; capacity modules.The target products include pentaerythritol tetraacrylate and tetramethacrylate, trimethylolpropane triacrylate and trimethacrylate, triethyleneglycol triacrylate and trimethacrylate, urethane dimethacrylate, isopropanol, ethanol, benzyl alcohol, ethylene glycol, allyl alcohol, diethyltoluamide, acetylsalicylic acid, acetanilide, polyethyleneglycol diacrylate, methyl acrylate, pentaerythritol tetracaprylate and tetracaprate and other products of the corresponding series.

[0092] Halogenation Platform

[0093] The platform is designed to implement halogenation reactions of alkanes, alkenes and alkynes, aromatic compounds, alcohols and carbonyl compounds, as well as fluorination reactions. The platform configuration includes: modules for feeding and preparing halogens (chlorine, bromine, iodine) and halogenating agents (thionyl chloride, N-bromosuccinimide, DAST); dynamic modules for feeding liquid feedstock; a corrosion-resistant reactor module (glass-lined, enameled or made of special alloys); heat exchange modules; pressure control modules; separation modules; product capacity modules; neutralization and detoxification modules. The target products include vinyl chloride, 1,2-dichloroethane, methylene chloride, chloroform, carbon tetrachloride, tetrachloroethylene, chlorobenzene, dichlorobenzene, chlorophenols, bromobenzene, 4-bromoanisole, iodomethane, methyl chloride, allyl chloride, allyl bromide, allyl alcohol, trifluoroacetic acid, benzyl chloride and other products of the corresponding series.

[0094] Oligomerization of Alkenes Platform

[0095] The platform is designed to implement the linear, cyclic and branched oligomerization of alkenes with the formation of α-olefins, cyclo-oligomers and branched oligomers. The platform configuration contains: alkene feeding and preparation modules; dynamic feeding modules; a reactor module (capacitive with a stirrer or tubular, depending on the subclass); heat exchange modules; pressure control modules; separation modules; a rectification unit if necessary; tank modules. The target products include hexene-1, octene-1, decene-1, dodecene-1, propylene trimers and tetramers, butylene dimers, trimers and tetramers and other products of the corresponding series.

[0096] Phosgenation Platform

[0097] The platform is designed for the implementation of amine and alcohol phosgenation reactions to form isocyanates and carbonates. The platform configuration includes: specially designed phosgene feed and preparation modules with a dual containment loop; amine and alcohol feed modules; a corrosion-resistant reactor module; heat exchange modules; pressure control modules; separation modules; product storage modules; modules for neutralization and detoxification of excess phosgene and hydrogen chloride. Particular attention is paid to safety systems, gas analysis, and emergency containment.

[0098] Diene Synthesis Platform

[0099] The platform is designed to implement [4+2] cycloaddition reactions (Diels-Alder reactions) between dienes and dienophiles with the formation of cyclohexene and other cyclic structures. The platform configuration contains: modules for feeding and preparing dienes and dienophiles; dynamic feeding modules; a reactor module (capacitive with a stirrer and a jacket or tubular); heat exchange modules; pressure control modules; separation modules; product capacity modules.

[0100] Biocatalysis Platform

[0101] The platform is designed to implement processes using enzymes and / or microorganisms as catalysts. The platform configuration includes: modules for preparing nutrient media and buffers; sterilization modules; a bioreactor module (with a stirrer, jacket, air or other gas sparging, pH, temperature, and dissolved oxygen control); heat exchange modules; separation modules; filtration and centrifugation modules; product concentration and conditioning modules; and capacity modules.

[0102] When implementing the method, the target organic synthesis product and the class of chemical reactions characterizing it are initially determined. Based on the identified reaction class, the appropriate process platform is selected from among the complex's predefined platform configurations, each of which is a pre-assembled subset of interchangeable process modules with a specified connection scheme, designed to implement a specific class of organic synthesis processes.

[0103] After selecting the process platform, the overall installation circuit is equipped with process modules of the selected platform configuration. The installed modules are interconnected by process lines, pipeline fittings, electrical and signal connections in accordance with the selected platform's process flow diagram and connected to the complex's overall distributed control system.

[0104] Modules are connected using standardized connecting elements, including flanged pipeline connections and quick-release electrical and signal connections, which ensure reproducible assembly of the process circuit, reduced installation and dismantling time, and a reduced likelihood of errors when reconfiguring the complex.

[0105] After assembling the selected platform configuration, the target organic synthesis process is carried out, with process parameters, including temperature, pressure, flow rates, and the composition of the process fluids, recorded. The material and energy balances of the process, as well as data on the properties of the resulting product, are simultaneously recorded.

[0106] The data obtained during the process are used to evaluate the activity, selectivity and stability of catalytic systems, optimize process modes, select rational process parameters and generate initial data for designing industrial production of the corresponding target product.

[0107] When switching to another target product, the complex is reconfigured by dismantling some of the process modules from the general assembly circuit and installing modules corresponding to the new platform configuration intended for the implementation of a different class of organic synthesis processes.

[0108] At the same time, unchangeable modules providing common functions are retained within the system. These modules may include air and nitrogen supply modules, water treatment modules, product neutralization and decontamination modules, general control system modules, and, if applicable to the new platform configuration, heat exchange and capacity modules.

[0109] After reconfiguring the complex, a new technological process is carried out in the assembled platform configuration without manufacturing a new technological complex as a whole, which ensures a reduction in the time required for reconfiguring production, a decrease in the volume of installation work, and an increase in the adaptability of the complex to various organic synthesis processes.

[0110] The claimed invention is carried out as follows.

[0111] Example 1. Obtaining isononanol on the oxo synthesis platform

[0112] The complex's common assembly circuit includes modules for syngas supply and preparation, a dynamic module for liquid feedstock (propylene trimers), a compressor module, a tubular reactor module loaded with a cobalt- or rhodium-containing homogeneous catalyst, heat exchange modules, high- and low-pressure separation modules, pressure control modules, and storage modules. Liquid feedstock is fed at a specified flow rate, and syngas is fed through the control modules. The reactor stream is cooled, the gas and liquid phases are separated, and the aldehyde fraction is sent for subsequent hydrogenation in the reactor module of the hydrogenation platform to produce isononanol. The material balance, target product selectivity, and byproduct composition are recorded.

[0113] Example 2. Obtaining aniline on a hydrogenation platform

[0114] The complex's common assembly circuit includes hydrogen supply and preparation modules, a dynamic nitrobenzene supply module, a tubular reactor module with a fixed bed of copper- or nickel-containing catalyst, heat exchange modules for heating the feed mixture and cooling the product, separation modules, and storage modules. The feedstock is fed through a preheater, the reaction occurs in the reactor module, the product stream is cooled, separated into gas and liquid phases, and the aniline is discharged to the storage module. The process parameters and product composition are recorded.

[0115] Example 3. Obtaining terephthalic acid on an oxidation platform

[0116] The complex's general assembly circuit includes compressed air supply and preparation modules, a dynamic liquid feedstock (p-xylene and solvent) supply module, a bubble reactor module with a stirrer and jacket, heat exchange modules (including a coolant circulation module with exothermic reaction heat recovery), pressure control modules, separation modules, product storage modules, and emission neutralization modules. The process is carried out in a bubble reactor at a specified temperature and pressure in the presence of a cobalt-manganese-bromide catalyst. The resulting product is filtered and sent for drying and analysis.

[0117] Example 4. Switching the complex from the oxosynthesis platform to the halogenation platform

[0118] After completing the work according to Example 1, the modules specific to the oxo synthesis platform (the tubular reactor module with a homogeneous catalyst, the high-pressure separation module, and the syngas feed module) are dismantled from the general assembly circuit. In their place, the halogenation platform modules are installed: a chlorine feed and preparation module, a corrosion-resistant reactor module, a hydrogen chloride neutralization module, and a separation module for separating halogenated products. The nitrogen and air feed modules, water treatment modules, the general control system, and some of the heat exchange modules are retained. After reconnection and leak testing, the complex is used for, for example, the synthesis of chlorobenzene from benzene and chlorine. The switchover time is determined by the composition of the modules being replaced and, as the applicant's experience shows, is significantly shorter than the time required to design and manufacture a new unit.

[0119] Example 5. Obtaining ethylbenzene on the alkylation platform

[0120] The complex's general assembly circuit includes benzene and ethylene feed and preparation modules, a dynamic benzene feed module, an ethylene compressor module, a reactor module with a fixed-bed zeolite catalyst, heat exchange modules, pressure and flow control modules, separation modules, a distillation unit, and storage modules. The process is carried out in the reactor module at a specified temperature and pressure; the resulting ethylbenzene is isolated in the distillation unit. Conversion, selectivity, and byproduct composition are recorded.

[0121] Thus, the claimed technical solution ensures the creation of a reconfigurable technological complex and a method for its use, intended for the implementation of various classes of organic synthesis processes on a single hardware base by selecting, assembling and operating pre-determined platform configurations of replaceable technological modules.

[0122] The proposed technical solution enables organic synthesis processes to be carried out on a pilot and industrial scale without the need to design and manufacture a new process unit when switching to a different target product. The use of predefined platform configurations, formed from functionally specialized modules, enables rapid reconfiguration of the complex by replacing, connecting, disconnecting, or adding individual process modules while maintaining the basic infrastructure of the complex.

[0123] The implementation of each process module in an individual metal frame as a structurally and functionally complete unit containing process equipment, piping, shut-off and control and safety valves, instrumentation and automated control equipment, as well as the use of unified mechanical, piping, electrical and information interfaces ensure the reproducibility of the assembly of platform configurations, a reduction in installation and dismantling time, a decrease in the likelihood of errors during reconfiguration of the complex and an increase in the technological flexibility of the system.

[0124] The construction of a control system for the complex based on distributed programmable logic controllers using standard industrial data transfer protocols ensures the integration of replaceable modules into a single control architecture while maintaining the autonomy of the electrical equipment and automation tools of individual modules.

[0125] The organization of replaceable process modules into organic synthesis platforms, each of which corresponds to a specific class of chemical reactions, ensures the adaptation of the complex to processes that impose different requirements on reactor units, heat exchange, reagent supply, phase separation, pressure regulation and flow rate of process media, and also allows the implementation of processes of oxo synthesis, hydrogenation, dehydrogenation, oxidation, alkylation, acylation, sulfation, sulfonation, nitration, hydrolysis, hydration, dehydration, esterification, amidation, halogenation, oligomerization of alkenes, phosgenation, diene synthesis and biocatalysis on a single hardware base.

[0126] The combination of essential features of the claimed technical solution ensures the achievement of the claimed technical result, which consists in expanding the technological capabilities of the complex, reducing the time and volume of work on restructuring production when switching between different target products, increasing the reproducibility of the assembly of process schemes, reducing the need to stop the complex when servicing individual modules and increasing the adaptability of the complex to various organic synthesis processes.

Claims

1. A reconfigurable technological complex for the implementation of organic synthesis processes, containing a common assembly circuit and a set of replaceable technological modules, each of which is made in an individual metal frame as a complete functional unit with technological equipment, piping, shut-off and control and / or safety valves, control and measuring instruments and means of connection to the general control system of the complex, characterized in that the replaceable technological modules are organized into technological platforms of organic synthesis in the form of predetermined platform configurations, each of which corresponds to a certain class of reactions of organic synthesis and contains a predetermined subset of replaceable technological modules with a given scheme of their connection, while the replaceable technological modules are made with unified mechanical, piping,electrical and information connection interfaces, and the general assembly circuit is designed with the possibility of replacing, connecting, disconnecting and / or adding replaceable technological modules when switching from one platform configuration to another without manufacturing a new complex as a whole, and some of the modules are designed with the possibility of being used simultaneously in several platform configurations without dismantling from the general assembly circuit of the complex.

2. The complex according to paragraph 1, characterized in that the replaceable process modules are selected from a group including reactor modules, heat exchange modules, capacity modules, separation modules, dynamic feedstock supply modules, compressor modules, pressure and / or flow control modules, special media supply and preparation modules, product neutralization and rendering harmless modules, catalytic packaging and catalyst regeneration modules and / or biocatalytic unit modules.

3. The complex according to paragraph 1, characterized in that the replaceable technological modules are equipped with their own switchgear cabinets and / or automated process control system cabinets or means of connection to the general distributed control system of the complex.

4. The complex according to paragraph 3, characterized in that the switchgear cabinets and the automated process control system are connected to the general control system via the ModbusRTU, ModbusTCP, OPCUA, Profinet protocols and / or equivalent industrial data transmission protocols.

5. The complex according to paragraph 1, characterized in that the technological platforms are designed to implement the processes of oxosynthesis, hydrogenation and dehydrogenation, oxidation, alkylation and acylation, sulfation, sulfonation and nitration, hydrolysis, hydration, dehydration, esterification and amidation, halogenation, oligomerization of alkenes, phosgenation, diene synthesis and / or biocatalysis.

6. The complex according to paragraph 1, characterized in that the connection of replaceable process modules is carried out by means of standardized flange connections of pipelines and quick-release electrical and signal connections.

7. The complex according to paragraph 1, characterized in that the unchangeable modules of the complex include at least air and nitrogen supply modules, water treatment modules, neutralization and decontamination modules, as well as a general control system for the complex.

8. A method for using a reconfigurable technological complex according to any one of paragraphs 1-7, including determining the target product of organic synthesis and the corresponding class of reactions, selecting the corresponding technological platform from among predetermined platform configurations, equipping the general assembly circuit of the complex with replaceable technological modules of the selected platform configuration, connecting the modules with technological lines and connecting them to the general control system of the complex, carrying out the process of organic synthesis with the registration of operating parameters, material and energy balances and data on the properties of the product, wherein when switching to another target product, replacing, disconnecting, connecting and / or adding a part of the replaceable technological modules in accordance with another platform configuration without manufacturing a new complex as a whole.

9. The method according to paragraph 8, characterized in that when switching between platform configurations, the complex retains unchanged modules, including at least air and nitrogen supply modules, water treatment modules, neutralization and decontamination modules, and the overall control system of the complex.

10. The method according to paragraph 8, characterized in that after assembly of the platform configuration, a tightness test of the process connections is carried out, a cold start with an inert environment is carried out, and a transition to the supply of the target process media is carried out after confirmation of the safety parameters.

11. The method according to paragraph 8, characterized in that the material and energy balances and data on the properties of the product recorded during the process are used to generate initial data in the design of industrial production.