ACFC Cooling Crystallization With Purge for Larger, Low-Color Crystals
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Solution Overview
Problem
There is a need for alternative and improved processes to produce 5-(alkoxycarbonyl)furan-2-carboxylic acids (ACFC) with high purity and low color, utilizing renewable resources as feedstocks to replace fossil-based aromatic dicarboxylic acids used in producing polyesters.
Innovation Solution
A method involving the oxidation of compounds like methyl 5-methylfuran-2-carboxylate (MMFC) using a cobalt, manganese, and bromine catalyst system in acetic acid solvent, followed by controlled cooling and crystallization to enhance crystal size and purity, minimizing impurities and color formation.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If conventional oxidation processes are used to produce ACFC, then production can proceed with standard methods, but the crystal size remains small and additional purification steps are required
Solution Approach 1:
The patent applies parameter changes by controlling the cooling rate from 0.5 to 10°C per minute and maintaining specific temperature ranges (30°C or less) to optimize crystal growth. This controlled thermal parameter change enables larger crystal sizes (20-500 microns) while achieving high purity in a single step, eliminating the need for additional purification operations.
2Productivity
If rapid cooling is applied to increase productivity, then cooling time is reduced, but crystal size becomes too small requiring further purification
Solution Approach 1:
The patent implements dynamics by allowing flexible cooling rates within the range of 0.5 to 10°C per minute, enabling the process to adapt to different production requirements. This dynamic approach permits faster cooling for high-volume production while still achieving adequate crystal sizes (20-500 microns) that meet purity specifications, thus maintaining both productivity and manufacturing precision.
3Manufacturing precision
If slow cooling is used to increase crystal size, then crystal quality improves, but production time increases
Solution Approach 1:
The patent optimizes the cooling rate parameter within the range of 0.5 to 10°C per minute to achieve the best compromise between crystal size and cooling time. By maintaining the temperature at 30°C or less and controlling the cooling rate, the process produces crystals of 20-500 microns in size within a reasonable time frame, simultaneously improving manufacturing precision while minimizing time loss.
4Ease of operation
If standard cooling rates are applied, then the process is simple to operate, but crystal size is insufficient for direct polymer production
Solution Approach 1:
The patent modifies the cooling rate parameter to a controlled range of 0.5 to 10°C per minute, which remains simple to operate but significantly improves crystal size to 20-500 microns. This parameter adjustment enables direct use in polymer production without requiring complex additional equipment or procedures, thus maintaining ease of operation while achieving the required manufacturing precision.
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 process achieves high yields of ACFC with particle sizes ranging from 20 to 500 microns, low impurity levels, and minimal color, enabling direct use in polymer production without additional purification steps, thus reducing costs and environmental impact.
Implementation Method 1
cooling the mixture from step (a) to a temperature of 30° C. or less at a rate of 0.5° C./min to 10° C./min
Implementation Method 2
a method for increasing the crystal size of a compound
Data Source
AI summary
A dried, solid composition comprising a compound of the structural formula (I) is provided: wherein R2 is an alkyl group having 1 to 6 carbon atoms, and wherein the composition has a particle/crystal size distribution of 20 to 500 microns; wherein the dried solid composition has a specific cake resistance of 5×109 m/kg or less, or 4.3×109 m/kg or less; wherein the particle size ranges from 20 to 500 microns. A process for making the composition is also provided.