Acrylonitrile Dimer Catalyst Recovery via Solvent Extraction
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Solution Overview
Problem
Existing methods for recovering acrylonitrile dimerization catalysts are inefficient, leading to high process loads and side reactions due to high boiling points and strong affinity between catalyst and acrylonitrile dimer, which increases operational costs.
Innovation Solution
A method involving multiple distillation and extraction steps using specific solvents like 1-hexene to separate and recover acrylonitrile dimerization catalysts, reducing the process load by preferentially removing reaction solvents and unreacted acrylonitrile before catalyst separation.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If distillation method is used to separate catalyst from reaction mixture, then catalyst recovery is achieved, but high temperature distillation causes side reactions
Solution Approach 1:
The patent introduces an extraction solvent as an intermediary substance to facilitate catalyst separation. The extraction solvent selectively extracts the catalyst from the reaction mixture at lower temperatures, avoiding direct high-temperature distillation of the catalyst-containing mixture and thereby preventing side reactions while achieving effective catalyst recovery
Solution Approach 2:
The patent changes the separation parameter from direct thermal distillation to solvent-based extraction followed by mild distillation. By altering the separation mechanism and using a two-stage process (extraction then distillation), the patent achieves catalyst recovery at lower temperatures, preventing thermal decomposition and side reactions
2Reliability
If extraction method is used to separate catalyst from reaction mixture, then separation is attempted, but high affinity between acrylonitrile dimer and catalyst makes separation difficult
Solution Approach 1:
The extraction solvent acts as a mediator that selectively interacts with the catalyst rather than the acrylonitrile dimer. This selective interaction overcomes the high affinity between catalyst and dimer by providing a preferential binding pathway, enabling effective separation despite the strong catalyst-dimer interaction
Solution Approach 2:
The patent applies local quality by selecting an extraction solvent with specific chemical properties that create selective affinity for the catalyst in certain regions of the reaction mixture. This localized selective extraction allows the catalyst to be separated from the dimer even when they have high mutual affinity, by creating a different chemical environment that favors catalyst-solvent interaction
3Reliability
If extraction method is used with considerable reaction solvent present, then catalyst separation is attempted, but process load is increased
Solution Approach 1:
The patent segments the separation process into two distinct stages: first removing the reaction solvent from the reaction mixture, then performing catalyst extraction on the solvent-free or low-solvent mixture. This segmentation reduces the process load by eliminating the need to handle large volumes of solvent during catalyst separation, while still achieving effective catalyst recovery
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
Efficient recovery of acrylonitrile dimerization catalysts is achieved while minimizing side reactions and process load, allowing for catalyst reuse and reducing operational costs.
Implementation Method 1
distilling the reaction product, recovering acrylonitrile and the reaction solvent
Implementation Method 2
mixing the extraction solvent with the materials supplied to the extraction column to separate layers, recovering an upper layer liquid containing the catalyst
Implementation Method 3
distilling the materials supplied to the second distillation column, recovering the extraction solvent at the upper part of the second distillation column, recovering the catalyst at the lower part
Data Source
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AI summary
A method for preparing an acrylonitrile dimer according to the present disclosure has the feature that it is possible to efficiently recover an acrylonitrile dimerization catalyst while reducing the process load.