Long-Chain Amino Acids and Dibasic Acids with Staged Neutralization
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Solution Overview
Problem
Existing processes for the production of long chain nylons are inefficient and uneconomical due to the inability to effectively separate and recover long chain amino acids, dibasic acids, alkyl amines, and alkanoic acids from their complex mixtures, leading to contamination and waste discharge.
Innovation Solution
A process involving hydrolysis with alkali or acid followed by distillation, acidification, and solvent extraction to separate and recover long chain amino acids and dibasic acids, utilizing solvents like toluene and acids with pKa <5.0 to form acid salts, allowing for effective phase separation and purification.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If step-wise neutralization in highly dilute concentration is used to isolate amino acids and dibasic acids, then the products can be obtained, but a substantial amount of energy is required for concentration making the process uneconomical
Solution Approach 1:
The patent changes the concentration parameter from highly dilute to concentrated state by reversing the neutralization process. Instead of neutralizing to isolation in dilute state and then concentrating, the method concentrates the reaction mixture first and then performs neutralization to precipitate products, eliminating the energy-intensive concentration step of dilute solutions.
Solution Approach 2:
The patent inverts the conventional isolation sequence: instead of isolating products in dilute state then concentrating, it concentrates the reaction mixture first and then isolates products through neutralization-induced precipitation. This reversal eliminates the need to concentrate large volumes of dilute product solutions.
2Ease of manufacture
If commercial starting materials containing various fatty acids are used, then production cost is reduced, but impurities contaminate the intended products requiring additional purification
Solution Approach 1:
The patent applies selective solubility properties at different pH levels to separate different components. By controlling the local chemical environment (pH) during neutralization, specific products precipitate while impurities remain in solution or precipitate at different stages, achieving purification without requiring high-purity starting materials.
Solution Approach 2:
The patent segments the purification process into multiple controlled neutralization stages where different products are precipitated sequentially based on their pKa values. This staged approach allows separation of amino acids, dibasic acids, and fatty acid impurities even when starting with commercially available materials containing various fatty acids.
3Productivity
If hydrolysis of mixed amide derivatives is performed, then long chain amino acids and dibasic acids are produced, but alkyl amines and alkanoic acids are also generated requiring separation
Solution Approach 1:
The patent utilizes parameter changes in pH to control the solubility and precipitation of different hydrolysis products. By adjusting pH during neutralization, amino acids and dibasic acids are selectively precipitated from the mixture containing alkyl amines and alkanoic acids, simplifying the separation process without requiring complex distillation or chromatography systems.
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
Achieves high-purity separation and recovery of long chain amino acids and dibasic acids with minimal waste discharge, improving process efficiency and reducing operational costs.
Implementation Method 1
Hydrolysis of the mixed amide derivatives from the Beckmann rearrangement yields not only long chain amino acids and long chain dibasic acids, but also alkyl amines and alkanoic acids
Implementation Method 2
A process involving hydrolysis with alkali or acid followed by distillation, acidification, and solvent extraction to separate and recover long chain amino acids and dibasic acids
Implementation Method 3
utilizing solvents like toluene and acids with pKa <5.0 to form acid salts, allowing for effective phase separation and purification
Implementation Method 4
A process involving hydrolysis with alkali or acid followed by distillation, acidification, and solvent extraction to separate and recover long chain amino acids and dibasic acids
Data Source
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AI summary
There is disclosed a process for the separation of long chain amino acid and long chain dibasic acid, comprising: (1) adding water and an extractant solvent to the aqueous suspension of an acid hydrolysis of the mixed amide derivatives to yield an aqueous solution and an extractant phase; (2) separating the mixture of step (1) into an aqueous phase containing the acid salt of long chain amino acid and alkylamine and an extractant phase containing long chain dibasic acid, short chain alkanoic acid, and impurities; (3) neutralizing the aqueous phase of step (2) with a basic agent to obtain a crystalline suspension of the long chain amino acid; (4) recovering the long chain amino acid by solid-liquid separation to yield an aqueous mother liquor; and (5) in the extractant phase of step (2), separating the long chain dibasic acid, short chain alkanoic acid, and impurities.