Acetone Methanol Removal via Segmented Distillation
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Solution Overview
Problem
The cumene-to-phenol process generates acetone with high residual methanol content, which reduces the life of resin catalysts used in producing bis-phenol-A, leading to increased production costs due to the difficulty in removing methanol using traditional distillation systems.
Innovation Solution
A method and system that involves oxidizing and cleaving cumene to produce a crude acetone product, neutralizing it, and then fractionating it in an acetone fractionation column to separate and remove methanol, using a methanol removal column to further reduce methanol concentration in the acetone product.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If traditional distillation systems are used to remove methanol from acetone, then the separation process is simple, but the methanol removal efficiency is insufficient (residual methanol content remains high)
Solution Approach 1:
The distillation system is segmented into multiple columns: a first distillation column for initial separation and a second distillation column for final methanol removal. This segmentation allows each column to be optimized for specific separation tasks, achieving low residual methanol content while managing system complexity through functional division.
Solution Approach 2:
The patent introduces a side-draw configuration in the first distillation column, adding a dimensional aspect to the separation process. By removing methanol-rich liquid from an intermediate side-draw point rather than only from the bottom, the system achieves more effective methanol removal while maintaining reasonable system complexity.
2Reliability
If methanol content in acetone is reduced, then catalyst life is extended, but the difficulty of removal increases due to azeotrope formation
Solution Approach 1:
The removal process is divided into two distillation columns, with the first column handling bulk methanol removal and the second column addressing residual methanol. This segmentation overcomes the azeotrope limitation by performing separation in stages, each optimized for its specific function.
Solution Approach 2:
The first distillation column performs preliminary methanol removal, reducing the methanol concentration before the second column processes the remaining methanol. This preliminary action reduces the difficulty of subsequent removal by working with lower methanol concentrations that are more amenable to separation.
3Manufacturing precision
If a multi-column distillation system is implemented, then methanol removal efficiency improves, but the system complexity and operational difficulty increase
Solution Approach 1:
The system is segmented into two columns with distinct functions: the first column handles initial methanol removal with a side-draw, while the second column performs final polishing. This functional segmentation allows each column to be operated with simpler controls optimized for its specific separation task.
Solution Approach 2:
The first column performs preliminary methanol removal, reducing the burden on the second column. By handling the bulk separation first, the system simplifies the operational requirements of the second column, which only needs to address residual methanol.
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 system effectively reduces methanol concentration in acetone to less than 100 ppm, thereby extending the life of resin catalysts and reducing production costs.
Implementation Method 1
The oxidation unit can receive cumene via line 112 and an oxidant via line 114 and to produce an oxidized product via line 116
Implementation Method 2
The CHP is then cleaved in the presence of an acid catalyst to form phenol and acetone
Implementation Method 3
The phenol and acetone stream is subsequently neutralized in a salt solution and thereafter fractionated to recover the end-products phenol and acetone
Data Source
AI summary
Methods and systems for producing low methanol concentration acetone are provided. The method can include oxidizing and cleaving cumene to produce a crude acetone product. The crude acetone product can be neutralized in a neutralization unit to produce a neutralized crude acetone product. The neutralized crude acetone product can be fractionated in an acetone fractionation column to produce an acetone product and an acetone bottoms product. Methanol can be removed from the acetone bottoms product to produce a methanol-depleted product. The methanol-depleted product can be introduced to the neutralization unit, a dephenolation unit, or both.