Integrated Acrolein Production via Glycerol Dehydration
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
The production of acrolein from propylene is dependent on fossil resources, contributing to greenhouse gas emissions, and existing methods are inefficient in terms of resource utilization and yield optimization.
Innovation Solution
A process involving the dehydration of glycerol in the presence of a propylene-comprising gas, where the dehydration reaction is integrated with the oxidation of propylene to efficiently produce acrolein, utilizing a catalyst with Hammett acidity H0 less than +2, and incorporating an endothermic dehydration reaction to cool and recover heat from the exothermic oxidation process.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If propylene is used as the starting material for acrolein production, then the production process is well-established and efficient, but dependence on fossil resources increases and greenhouse gas emissions are contributed
Solution Approach 1:
The patent combines two separate processes (propylene oxidation and glycerol dehydration) into a single integrated process. The glycerol dehydration reaction is performed in the presence of the propylene oxidation reaction gas, allowing both reactions to occur simultaneously in the same reactor system. This merging enables the use of renewable glycerol while maintaining efficient acrolein production, thereby reducing dependence on fossil resources without sacrificing productivity.
Solution Approach 2:
The reaction system is designed to perform multiple functions simultaneously: it oxidizes propylene to acrolein while also dehydrating glycerol to acrolein. The catalyst system and reaction conditions are optimized to support both reactions, making the process universally applicable to multiple feedstock types (both fossil-based propylene and renewable glycerol), thus reducing harmful emissions while maintaining production efficiency.
2Object-generated harmful factors
If glycerol dehydration is performed to produce acrolein, then renewable starting material is used and greenhouse gas emissions are reduced, but the reaction requires specific temperature and pressure conditions to displace the equilibrium
Solution Approach 1:
The patent merges the glycerol dehydration reaction with the propylene oxidation reaction in a single process. The propylene oxidation reaction provides a source of acrolein and occurs under conditions that also favor glycerol dehydration. By combining these reactions, the process achieves glycerol conversion to acrolein without requiring separate complex equipment for temperature and pressure control, as both reactions are driven by the same reaction conditions.
Solution Approach 2:
The patent establishes a continuous process where glycerol dehydration occurs continuously in the presence of the propylene oxidation reaction gas. The reaction system maintains continuous operation with steady-state temperature and pressure conditions, eliminating the need for complex batch-wise control adjustments. The continuous flow of reaction gas through the catalyst bed ensures consistent conversion of glycerol to acrolein under optimized conditions.
3Productivity
If the dehydration reaction is promoted at high temperatures, then acrolein yield increases, but energy consumption increases and heat management becomes more difficult
Solution Approach 1:
The patent combines the endothermic glycerol dehydration reaction with the exothermic propylene oxidation reaction. The heat generated by the oxidation reaction provides the necessary thermal energy for the dehydration reaction, reducing the need for external heating and lowering overall energy consumption. This merging of reactions with opposite thermal characteristics allows high acrolein yield from glycerol without proportionally increasing energy input.
Solution Approach 2:
The patent converts the thermal energy that would otherwise be wasted heat from the exothermic oxidation reaction into useful thermal energy driving the dehydration reaction. By utilizing the heat generated in situ, the process transforms a potential energy loss into a beneficial contribution toward achieving high acrolein yield from glycerol, thereby reducing net energy consumption while maintaining high productivity.
4Productivity
If existing acrolein production units are expanded, then production capacity increases, but dependence on fossil resources and associated environmental issues are not addressed
Solution Approach 1:
The patent creates a universal process that can handle multiple feedstock types (propylene and glycerol) using the same reactor and catalyst system. This multi-functional approach allows existing production units to process renewable glycerol alongside or instead of fossil-based propylene, thereby increasing production capacity while simultaneously reducing fossil resource dependence and associated environmental harm.
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 approach increases acrolein production while reducing dependence on fossil resources, enhances yield recovery, and aligns with green chemistry principles by using renewable biomass-derived glycerol, thereby minimizing greenhouse gas emissions.
Implementation Method 1
the dehydration reaction of glycerol makes it possible to cool the reaction gases resulting from the stage of oxidation of the propylene to give acrolein
Implementation Method 2
The reaction can be carried out in the liquid phase or in the gas phase. This type of reaction is known to be catalyzed by acids
Implementation Method 3
the dehydration reaction of glycerol makes it possible to cool the reaction gases resulting from the stage of oxidation of the propylene to give acrolein
Data Source
AI summary
The invention relates to a method for preparing acrolein from propylene, consisting of a first glycerol dehydration step preformed in the presence of a gas containing propylene and, more specifically, in the presence of the reaction gas originating from the propylene to acrolein oxidation step. The inventive method enables the use, in part, of renewable raw material, while increasing acrolein production.