Acetone Column Water Injection for Low-Aldehyde Dry Product
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Solution Overview
Problem
Existing processes struggle to efficiently remove aldehydes from acetone due to limitations in water concentration, making it difficult to optimize column conditions and produce a drier acetone product suitable for new markets, particularly electronic-grade acetone, without requiring costly column expansions.
Innovation Solution
Injecting liquid water below the feed tray of the acetone column to absorb aldehydes and aldol products, optimizing the location and flow rate of water streams to enhance aldehyde removal, using caustic catalysis in a counter-current contacting zone within the column.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If water concentration is increased in the reaction zone to improve aldehyde removal, then aldehyde removal efficiency is improved, but water concentration in acetone product exceeds maximum allowable limits
Solution Approach 1:
The invention divides the water addition function into two separate locations: (1) water is added at the caustic addition point to enable aldehyde removal reactions, and (2) additional water is injected below the feed tray to absorb aldehydes and aldol products in the reaction zone. This segmentation allows each water addition to serve a specific function without compromising product specifications.
Solution Approach 2:
The invention introduces an intermediary water stream injected below the feed tray that acts as a mediator between the reaction zone and the product. This water stream absorbs aldehydes and aldol products formed in the reaction zone, preventing them from contaminating the acetone product while allowing the reaction to proceed effectively.
2Manufacturing precision
If column size is increased to accommodate water-rich zone relocation, then drier acetone product can be produced, but capital cost increases significantly
Solution Approach 1:
The invention changes the operational parameters by injecting liquid water at a specific location below the feed tray at optimized flow rates. This parameter change enables the water-rich zone to be effectively relocated without physical column modifications, achieving drier acetone product while avoiding capital-intensive column expansions.
3Reliability
If water is injected at traditional locations to remove aldehydes, then aldehyde removal is achieved, but product water content exceeds specifications
Solution Approach 1:
Instead of adding water at traditional locations (caustic addition point or upper column), the invention inverts the approach by injecting water below the feed tray, which is a non-traditional location. This inverted water addition strategy enables effective aldehyde removal while maintaining product water content within specifications.
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
Achieves a very low concentration of aldehydes in the acetone product, enabling sale into new markets and improving phenol unit quality by effectively managing the aqueous phase within the column.
Implementation Method 1
This additional water efficiently absorbs aldehydes and aldehyde condensation products (aldols) from the reaction zone and rejects them to the bottom of the acetone column
Implementation Method 2
aldehyde removal is improved by the presence of more water further up the column, closer to the product tray. However, the acetone product has limitations on the maximum concentration of water. The maximum allowable water, and also aldehyde, are generally decreasing thus making column optimization difficult.
Implementation Method 3
reacting the aldehydes with caustic in an acetone column and washing the organic phase with a plurality of water streams
Data Source
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AI summary
The present invention relates to process and apparatus for removing aldehydes from acetone. More specifically, the present invention relates to a process and apparatus for removing aldehydes from acetone by reacting the aldehydes with caustic in an acetone column and washing the organic phase with a plurality of water streams.