Anhydrosugar Alcohol Production via Solid Acid Catalyst and Melt Crystallization
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Solution Overview
Problem
Current methods for producing anhydrosugar alcohols, such as isosorbide, face challenges including reactor corrosion, high energy consumption, and decreased yield due to the use of strong acid catalysts and vacuum distillation processes, which increase production costs and complicate the separation process.
Innovation Solution
A method involving the reaction of sugar alcohols with an acid catalyst in a reactor, followed by distillation and subsequent melt crystallization to produce high-purity anhydrosugar alcohol, utilizing a catalyst with specific properties to maintain activity and separate effectively, and incorporating a recycle process to enhance yield and purity.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If sulfuric acid is used as a catalyst and reaction is carried out under reduced pressure, then anhydrosugar alcohol can be produced, but reactor corrosion occurs and expensive equipment is required
Solution Approach 1:
The patent replaces expensive corrosion-resistant reactors with ordinary reactors by using a solid acid catalyst that eliminates the need for vacuum conditions. The catalyst can be easily replaced if needed, making the system more economical despite the reactor's shorter service life
Solution Approach 2:
The patent changes the reaction parameters from vacuum conditions to atmospheric pressure, and from strong liquid acid catalyst to solid acid catalyst. This parameter change resolves the corrosion problem while maintaining production efficiency
2Manufacturing precision
If vacuum distillation is used to separate anhydrosugar alcohol, then separation can be achieved, but energy consumption increases and production cost increases
Solution Approach 1:
The patent changes the distillation parameter from vacuum to atmospheric pressure, eliminating the need for vacuum equipment and the continuous energy consumption associated with maintaining vacuum conditions, while still achieving effective separation
Solution Approach 2:
The patent extracts the vacuum requirement from the distillation process by using atmospheric pressure distillation combined with melt crystallization, removing the energy-intensive vacuum maintenance step
3Manufacturing precision
If multi-step process is carried out under vacuum, then anhydrosugar alcohol can be separated, but yield decreases and production cost increases
Solution Approach 1:
The patent merges the reaction and distillation steps into a simultaneous process, and combines atmospheric pressure distillation with melt crystallization to achieve purification in fewer steps, thereby maintaining higher yield while reducing production cost
4Use of energy by stationary object
If atmospheric pressure distillation is used, then energy consumption is reduced, but anhydrosugar alcohol decomposes due to high boiling point
Solution Approach 1:
The patent utilizes phase transition by combining atmospheric pressure distillation with melt crystallization. The crystallization step occurs at lower temperatures, preventing decomposition while the distillation step operates at atmospheric pressure to reduce energy consumption
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 method achieves high-yield, high-purity anhydrosugar alcohol production with reduced energy consumption and costs, avoiding reactor corrosion and the need for expensive equipment, while simplifying the separation process through direct distillation and melt crystallization.
Implementation Method 1
reacting a sugar alcohol in a presence of an acid catalyst in a reactor
Implementation Method 2
evaporating a reaction product
Implementation Method 3
cooling an evaporated product, thereby obtaining a crude anhydrosugar alcohol
Implementation Method 4
introducing the crude anhydrosugar alcohol into a melt crystallization process, thereby obtaining a high-purity anhydrosugar alcohol
Data Source
AI summary
The present invention relates to a method of producing and purifying a high-purity anhydrosugar alcohol in high yield by a simple process and apparatus, the method includes the steps of: allowing a sugar alcohol to react in the presence of an acid catalyst in a reactor, and, at the same time, evaporating a product of the reaction; cooling the evaporated product to remove water and obtain a crude anhydrosugar alcohol; and introducing the crude anhydrosugar alcohol into a melt crystallization process to obtain a high-purity anhydrosugar alcohol.