Acesulfame Spray Reactor Flow Velocity Optimization
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Solution Overview
Problem
Current processes for producing acesulfame and its derivatives face challenges in yield, post-treatment requirements, side product proportion, crystallization losses, and environmental impact, necessitating improved methods for efficient production.
Innovation Solution
A process involving contacting SO3 and acetoacetamide-N-sulfonic acid in a reactor with a controlled velocity of flow exceeding 0.9 m/s, followed by rapid external pressure drop and subsequent hydrolysis with water, to enhance yield, reduce side products, and minimize environmental impact.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If conventional processes are used for acesulfame production, then the production can proceed with standard equipment and conditions, but the yield is reduced and side product proportion increases
Solution Approach 1:
The patent applies parameter changes by optimizing the velocity of flow through the reactor to a specific range (0.9-10 m/s) and controlling the residence time (0.1-10 seconds). These parameter modifications transform the reaction conditions to achieve higher yield (90-99%) and minimize side product formation, directly resolving the technical contradiction between productivity and harmful factors.
Solution Approach 2:
The patent implements dynamics by introducing a controlled velocity of flow through the reactor rather than using static conditions. The dynamic flow regime allows reactants to pass through the reaction zone with optimized residence time, enhancing reaction efficiency and selectivity, thereby improving yield while reducing side products.
2Ease of manufacture
If conventional processes are used for acesulfame production, then the process can proceed with standard treatment steps, but post-treatment requirements increase
Solution Approach 1:
The patent applies preliminary action by optimizing the reaction conditions in advance (velocity of flow 0.9-10 m/s, residence time 0.1-10 seconds) to produce high-purity acesulfame directly. This preliminary optimization of reaction parameters reduces the need for extensive post-treatment steps, as the reaction already achieves 90-99% yield with minimal side products.
3Loss of substance
If conventional crystallisation processes are used, then the product can be recovered, but product loss during crystallisation increases
Solution Approach 1:
The patent applies parameter changes by controlling the velocity of flow and residence time to optimize the reaction outcome, which directly impacts the crystallisation step. By achieving higher conversion and selectivity in the reaction zone, less acesulfame remains in the mother liquor during crystallisation, reducing product loss and improving overall yield.
4Object-affected harmful factors
If conventional processes are used for acesulfame production, then the process can proceed with standard methods, but environmental impact increases
Solution Approach 1:
The patent applies parameter changes by optimizing the velocity of flow (0.9-10 m/s) and residence time (0.1-10 seconds) to achieve high yield (90-99%) with minimal side products. This reduces waste stream composition and volume, thereby lowering environmental impact while maintaining or improving productivity.
Solution Approach 2:
The patent converts what would normally be harmful side products into a benefit by optimizing reaction conditions to minimize their formation. The controlled velocity of flow and residence time ensure high selectivity, transforming the potential harm of side product formation into the benefit of clean, efficient production with reduced environmental burden.
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
This process improves the yield, reduces the need for post-treatment, minimizes side product formation, and decreases product loss during crystallization, while also lowering the environmental footprint of acesulfame production.
Implementation Method 1
The product exiting the reactor to a region outside the reactor through an aperture at a velocity of flow higher than 0.9 m/s, the region outside the reactor having an external pressure which is lower than the reactor pressure
Data Source
AI summary
In general, the invention relates to a process for the preparation of acesulfame or a derivative thereof. More specifically, the invention relates to a process, to a product obtainable by the process and the use of a specified velocity of flow for improving yield in the preparation of acesulfame or a derivative thereof. The invention relates to a process for the preparation of a product, the product being 6-methyl-3,4-dihydro1,2,3-oxathiazin-4-one 2,2-dioxide or a derivative thereof, the process comprising the following steps: a. Contacting SO3 and acetoacetamide-N-sulfonic acid or a derivative thereof in a reactor with a reactor pressure to obtain the product; b. The product exiting the reactor to a region outside the reactor through an aperture at a velocity of flow higher than 0.9 m/s, the region outside the reactor having an external pressure which is lower than the reactor pressure.