13C-Urea Continuous-Flow Synthesis with Even Mixing and High CO Conversion
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Solution Overview
Problem
Existing methods for synthesizing 13C-urea face challenges due to poor CO2 conversion and are not suitable for industrial production, leading to low yield and purity.
Innovation Solution
A continuous-flow synthesis method involving the reaction of 13CO, sulphur, and NH3 in methanol in a continuous-flow reactor under controlled conditions, with even mixing and gas-liquid separation, achieving 95-100% CO conversion and 90-95% yield.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If traditional high-temperature and high-pressure reaction between CO2 and NH3 is used, then urea synthesis can be achieved, but CO2 conversion is poor and the method is not suitable for industrial production
Solution Approach 1:
The patent changes the reaction parameters by using 13CO instead of CO2, employing a different chemical pathway that achieves over 95% conversion efficiency. The continuous-flow reactor maintains controlled temperature (50-150°C) and pressure (0-5 MPa) conditions, improving both productivity and conversion reliability compared to traditional high-temperature high-pressure methods
Solution Approach 2:
The patent extracts and addresses the specific problem of poor CO2 conversion by completely changing the carbon source from CO2 to 13CO, thereby eliminating the conversion bottleneck that limited traditional urea synthesis methods for industrial application
2Quantity of substance
If existing synthesis methods are used, then urea can be produced, but yield and purity are low
Solution Approach 1:
The patent employs a continuous-flow reactor that maintains continuous reaction conditions, ensuring consistent product quality and high yield (90-95%). The continuous flow system with proper mixing and controlled residence time (1-120 min) eliminates batch-to-batch variations, achieving both high quantity and high purity 13C-urea suitable for industrial production
Solution Approach 2:
The patent uses an intermediary approach by introducing a mixing unit that ensures even distribution of reactants before they enter the reactor. This intermediary mixing step prevents local inconsistencies that would lead to impurities, while the continuous-flow system acts as an intermediary mechanism to maintain optimal reaction conditions throughout the process
3Productivity
If continuous-flow synthesis is implemented, then large-scale production is enabled, but mixing uniformity must be maintained to prevent pipeline blockage
Solution Approach 1:
The patent applies preliminary action by incorporating a mixing unit before the continuous-flow reactor. This preliminary mixing ensures that solid particles are evenly suspended in the liquid phase before entering the reaction system, preventing pipeline blockage and enabling smooth large-scale continuous production
Solution Approach 2:
The patent uses hydraulic principles in the continuous-flow system where liquid phase carries solid particles through the reactor. The fluid flow dynamics ensure continuous movement and even distribution of materials, enabling large-scale production while maintaining mixing uniformity through proper flow rate control (0.001-10 L/min)
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
The method provides high-quality 13C-urea with improved yield and safety, enabling large-scale production with reduced costs and minimal pollution.
Implementation Method 1
the reaction of 13CO, sulphur, and NH3 in methanol in a continuous-flow reactor under controlled conditions
Implementation Method 2
even mixing of the reaction materials
Implementation Method 3
gas-liquid separation
Data Source
AI summary
A continuous-flow synthesis method of 13C-urea, including: (S1) mixing sulphur and a methanol solution containing NH3 in a feed kettle to obtain a slurry; or mixing ammonia gas, sulphur and methanol in a feed kettle to obtain a slurry; (S2) feeding the slurry into a mixing unit; and feeding 13CO into the mixing unit to obtain a three-phase mixture; (S3) mixing the three-phase mixture in the mixing unit evenly; feeding the three-phase mixture into a continuous-flow reactor for reaction to obtain a reaction product; and (S4) feeding the reaction product into a gas-liquid separator for gas-liquid separation, and collecting a liquid phase as a crude product solution; and subjecting the liquid phase to purification to obtain the 13C-urea.