Acrylic Acid By-Product Hydrolysis Before Continuous Cracking
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Solution Overview
Problem
The regeneration of acrylic acid from heavy by-products in acrylic acid production units is hindered by the increase in viscosity of the residue during thermal cracking, leading to inefficiencies and operational challenges, particularly when dependent on other production units or requiring additional solvents.
Innovation Solution
A process combining batch hydrolysis with continuous thermal cracking, utilizing a hydrolyzer to reduce the viscosity of heavy by-products from acrylic acid production units, followed by thermal cracking to recover acrylic acid, without dependency on other units and solvent addition.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If thermal cracking is carried out to regenerate acrylic acid from heavy by-products, then acrylic acid recovery efficiency is improved, but residue viscosity increases greatly
Solution Approach 1:
The patent applies preliminary action by conducting hydrolysis treatment on the heavy by-products before thermal cracking. This pre-treatment converts ester compounds into carboxylic acids, which prevents excessive viscosity increase during subsequent cracking operations. The hydrolyzed feedstock is then processed in the cracker, achieving high acrylic acid recovery while maintaining manageable residue viscosity levels.
2Stability of the object's composition
If co-cracking with acrylic ester heavy products is implemented, then residue viscosity is reduced, but dependency on other production units increases
Solution Approach 1:
The patent applies self-service by implementing hydrolysis of the heavy by-products themselves to generate the desired effect (reduced viscosity) without needing external materials or processes. The hydrolysis converts the ester compounds within the AAHP into carboxylic acids, which inherently prevent viscosity buildup during cracking. This eliminates dependency on separate ester production units while achieving the same viscosity control effect.
3Stability of the object's composition
If solvents are added to manage residue viscosity, then residue fluidity is improved, but process complexity and equipment costs increase
Solution Approach 1:
The patent applies self-service by using the heavy by-products themselves as the source of viscosity control through hydrolysis. The ester compounds in the feedstock are converted to carboxylic acids during hydrolysis, which then act as internal viscosity modifiers during cracking. This eliminates the need for external solvent addition systems, mixing equipment, and associated process complexity.
Solution Approach 2:
The patent applies parameter changes by modifying the chemical composition of the feedstock through hydrolysis treatment. The conversion of esters to carboxylic acids changes the molecular properties of the material being cracked, resulting in residue with inherently lower viscosity that requires no additional solvents or complex equipment to manage.
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
Enhances the recovery of acrylic acid by reducing residue viscosity and minimizing discharge, while maintaining operational simplicity and reducing equipment costs.
Implementation Method 1
introducing said heavy by-products with water into a hydrolyzer and subjecting them to batch hydrolysis
Implementation Method 2
cracking carried out continuously... thermal cracking process that regenerates acrylic acid
Data Source
AI summary
A process for regenerating acrylic acid (AA), by thermal cracking, from heavy by-products (residues referred to as AAHP) from an AA production unit, with a view to recycling them in the acrylic acid production plant. This process includes two steps: hydrolysis carried out batchwise, and cracking carried out continuously, and improves the current performance of cracking plants.