Acrylamide Production via Microbial Catalyst Hydration
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Solution Overview
Problem
The existing processes for producing acrylamide using microbial catalysts with nitrile hydratase result in lower acrylamide concentrations after impurity separation, necessitating additional steps like distillation, increasing production costs and complexity.
Innovation Solution
A process involving a hydration reaction of acrylonitrile using a microbial catalyst containing nitrile hydratase followed by impurity removal with activated carbon in an acidic condition, then filtration and washing, to achieve an acrylamide aqueous solution with a concentration of 40 to 60% by weight, simplifying production steps and reducing costs.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If acrylamide aqueous solution is produced using microbial catalyst and then separated from impurities, then impurity removal is achieved, but the concentration of acrylamide is further lowered requiring additional concentration steps
Solution Approach 1:
The patent applies preliminary action by conducting the hydration reaction under controlled conditions that pre-optimze the acrylamide concentration before impurity separation. The reaction is performed with specific parameters (acrylonitrile concentration 10-50%, water 50-90%, catalyst 0.01-5% based on acrylonitrile mass, temperature 20-60°C, reaction time 1-48 hours) to ensure the product solution already contains acrylamide at a concentration that will remain suitable after separation, eliminating the need for post-separation concentration steps.
2Quantity of substance
If additional concentration steps like distillation are performed to maintain acrylamide concentration, then product concentration is improved, but production cost increases
Solution Approach 1:
The patent applies self-service by designing a reaction system where the acrylamide concentration is naturally maintained at optimal levels through the hydration reaction itself. By controlling the reaction conditions (substrate concentration, catalyst amount, temperature, time), the system self-regulates to produce acrylamide at the desired concentration range, eliminating the need for energy-intensive distillation or concentration steps and thereby reducing production costs.
3Quantity of substance
If acrylonitrile concentration is increased to maintain product concentration after separation, then acrylamide concentration is improved, but reaction conditions become more difficult to control
Solution Approach 1:
The patent applies parameter changes by establishing specific optimal ranges for multiple reaction parameters simultaneously: acrylonitrile concentration (10-50%), water (50-90%), catalyst amount (0.01-5% based on acrylonitrile mass), temperature (20-60°C), and reaction time (1-48 hours). This multi-parameter optimization ensures that even with higher acrylonitrile feed concentration, the reaction remains easy to control and produces acrylamide at the desired concentration after separation.
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 allows for a simplified production process and reduced costs by maintaining higher acrylamide concentrations throughout the process, eliminating the need for additional concentration steps like distillation, and producing a high-quality acrylamide solution suitable for polymerization.
Implementation Method 1
a step of allowing acrylonitrile to undergo hydration reaction by the use of a microbial catalyst containing nitrile hydratase
Implementation Method 2
acrylonitrile is hydrated by an enzyme contained in the microorganism, i.e., nitrile hydratase, and thereby converted into acrylamide
Implementation Method 3
the removal of impurities in step (b) comprises bringing the reaction solution (I) into contact with activated carbon in an acidic condition
Data Source
AI summary
[Problem] To provide a process for producing (meth)acrylamide using a microbial catalyst, wherein production steps can be simplified and production cost can be reduced. [Means for solving problem] The process for producing (meth)acrylamide of the present invention is a process comprising (a) a step of allowing (meth)acrylonitrile to undergo hydration reaction by the use of a microbial catalyst containing nitrile hydratase in an aqueous medium to obtain a (meth)acrylamide reaction solution (I) and (b) a step of removing impurities from the reaction solution (I) to obtain a (meth)acrylamide aqueous solution (II), wherein the concentration of (meth)acrylamide in the reaction solution (I) obtained in the step (a) is higher than the concentration of (meth)acrylamide in the aqueous solution (II) obtained in the step (b) by 2 to 20% by weight.