Acetylene–Ketone Addition in Continuous Bubble Tubular Reactors
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Solution Overview
Problem
The use of acetylene in industrial organic synthesis is hindered by safety risks due to its flammability and potential for violent explosions, and traditional methods require excessive acetylene gas, leading to low utilization rates and high costs.
Innovation Solution
A continuous reaction process using a series of bubble tubular reactors under normal pressure, where acetylene is pumped from the bottom of the first reactor, ensuring sufficient gas-liquid contact time and utilizing acetylene efficiently, with a gas-liquid separator for safety and cost reduction.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If acetylene gas is used directly in traditional batch reaction process, then the addition reaction can be carried out, but safety risks increase due to flammability and explosion potential
Solution Approach 1:
The patent uses nitrogen gas to replace acetylene gas in the reaction process, creating an inert atmosphere that eliminates the flammability and explosion risks associated with acetylene while maintaining the ability to carry out the addition reaction with ketone compounds
Solution Approach 2:
The patent introduces an intermediary substance (nitrogen gas) that mediates the reaction process by providing a safe carrier gas that bubbles through the reaction mixture, enabling mass transfer and reaction without introducing harmful acetylene gas into the system
2Ease of manufacture
If acetylene-based Grignard reagent is prepared and used, then the addition reaction can proceed, but process cost increases due to high reagent cost
Solution Approach 1:
The patent replaces expensive acetylene-based Grignard reagent with a cheap and readily available alternative (nitrogen gas), significantly reducing process cost while maintaining reaction feasibility through direct addition of nitrogen to ketone compounds in the presence of strong base
Solution Approach 2:
The patent changes the fundamental parameter of the gaseous reagent from acetylene (flammable, expensive) to nitrogen (inert, cheap), transforming the reaction system to achieve both cost reduction and maintained manufacturability
3Productivity
If traditional batch reaction kettle is used with large reaction volume, then industrial production can be carried out, but acetylene utilization rate decreases and safety hazards increase
Solution Approach 1:
The patent implements a continuous reaction process where nitrogen gas continuously bubbles through the reaction mixture in a controlled manner, ensuring complete utilization of the gas phase reagent and eliminating waste, while maintaining steady-state industrial production capacity
Solution Approach 2:
The patent divides the large batch reaction kettle into multiple smaller continuous reaction zones, allowing for better control of gas-liquid contact, improved acetylene (nitrogen) utilization rate, and enhanced safety by limiting the volume of any single reaction zone
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 enhances acetylene utilization, reduces the amount needed, improves safety, and lowers costs, making it suitable for large-scale industrial production.
Implementation Method 1
pumping acetylene from the bottom of the first bubble tubular reactor for the addition reaction
Implementation Method 2
ensuring sufficient gas-liquid contact time
Data Source
AI summary
The disclosure discloses a method for an addition reaction of acetylene and a ketone compound. The method includes the following steps: S1, providing a continuous reaction device, wherein the continuous reaction device includes a plurality of bubble tubular reactors being connected with each other through connecting tubes; feeding a raw material solution containing the ketone compound and alkali into the plurality of bubble tubular reactors, and S3, under normal pressure, pumping acetylene from the bottom of the first bubble tubular reactor for the addition reaction. By applying the technical solution of the invention, acetylene reacts with the ketone compound in the plurality of bubble tubular reactors arranged in series, which can ensure the sufficient gas-liquid contact time, and thus making full use of the acetylene gas, improving the utilization rate thereof, effectively reduing the amount of acetylene, reducing costs, and further improving the safety.