Acyl Peroxide Production via pH-Controlled Hydroperoxide Recycling
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Solution Overview
Problem
Existing processes for preparing acyl peroxides from organic hydroperoxides do not effectively recover and recycle unconverted hydroperoxide, leading to inefficiencies and impurities in the final product.
Innovation Solution
A process involving the reaction of an acyl compound with an organic hydroperoxide and an aqueous base, followed by pH adjustment to separate and recycle the unconverted hydroperoxide, ensuring its majority remains in the organic phase for reuse, thereby achieving high conversion and low impurity levels.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If organic hydroperoxide is used in stoichiometric excess to achieve maximum conversion of acyl compound, then conversion of acyl compound is improved, but unconverted hydroperoxide remains in the reaction mixture causing product impurity
Solution Approach 1:
The patent adjusts the pH parameter of the aqueous phase to a specific range (6-13, preferably 11-12.5) to control the distribution of unconverted hydroperoxide between phases. By changing this chemical parameter, the hydroperoxide is preferentially transferred to the aqueous phase while the acyl peroxide remains in the organic phase, resolving the contradiction between high conversion and low impurity
Solution Approach 2:
The patent extracts unconverted hydroperoxide from the organic reaction mixture into an aqueous phase through pH-controlled liquid-liquid extraction. This separation removes the harmful impurity (unconverted hydroperoxide) from the product-containing organic phase, achieving both high conversion and low impurity levels
2Device complexity
If unconverted hydroperoxide is discarded without recovery, then process simplicity is maintained, but material efficiency and productivity deteriorate
Solution Approach 1:
Instead of discarding unconverted hydroperoxide, the patent recovers it by extracting into the aqueous phase and then recycling it back to the reaction system. This recovery approach improves material efficiency and productivity while adding only moderate process complexity through pH adjustment and phase separation steps
Solution Approach 2:
The patent implements a feedback loop where unconverted hydroperoxide is continuously recovered from the reaction mixture, purified through pH-controlled extraction, and fed back into the reaction system. This closed-loop approach maximizes material utilization and maintains high productivity
3Manufacturing precision
If multiple washing stages are used to remove unconverted hydroperoxide, then product purity is improved, but process complexity and waste generation increase
Solution Approach 1:
The patent achieves high product purity through a single pH-controlled extraction stage rather than multiple washing stages. By adjusting the pH parameter to 6-13, the hydroperoxide selectively partitions into the aqueous phase, accomplishing purification in one step and reducing process complexity
Solution Approach 2:
The patent introduces an aqueous base solution as an intermediary medium to facilitate selective extraction of hydroperoxide. This intermediary phase enables efficient separation of hydroperoxide from acyl peroxide through pH-controlled partitioning, achieving high purity without requiring multiple washing operations
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 process allows for virtually complete conversion of hydroperoxide to acyl peroxide with reduced wastewater pollution and higher product purity by recycling unconverted hydroperoxide, using an excess hydroperoxide without increasing stoichiometric consumption.
Implementation Method 1
extracting the organic phase obtained in step c) with an aqueous solution of a base
Implementation Method 2
separating the biphasic mixture obtained in step b) into an aqueous phase and an organic phase
Data Source
AI summary
The invention relates to a method for producing acyl peroxides. According to the method, an acyl compound is reacted with an organic hydroperoxide and a base, to generate a two-phase mixture. The pH of the two-phase mixture is adjusted to 6 to 13. The obtained organic phase is extracted with an aqueous solution of a base and the aqueous extract is recirculated to the reaction step. The method according to the invention allows the recirculation of unreacted hydroperoxide to the reaction step.