Batch Esterification Pressure Profile for Higher Conversion
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Solution Overview
Problem
Existing batch processes for preparing ester-based plasticizers are costly and inefficient, lacking optimization of reaction conditions to achieve high conversion rates, uniform product quality, and reduced energy consumption.
Innovation Solution
A method for preparing ester-based materials by controlling pressure in a batch reactor, with early and latter stages set at specific pressure ranges (0.3 barg to 1.0 barg and 0 barg to 0.5 barg, respectively, and dividing the reaction stages based on conversion rates (30% to 90%), along with catalyst addition and controlled alcohol input.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If batch processing is used for preparing ester-based plasticizer, then the process is widely applied and relatively simple, but the conversion rate is low and reaction duration is long
Solution Approach 1:
The patent applies dynamic pressure control by adjusting reactor pressure during different stages of the reaction process. The pressure is increased to supercritical conditions during the reaction and then rapidly decompressed, creating dynamic changes in reaction conditions that enhance conversion rate while maintaining process simplicity.
Solution Approach 2:
The patent changes physical parameters by transitioning to supercritical conditions through pressure and temperature adjustment, then rapidly decompressing. This parameter change enables high conversion rates in a batch process without requiring complex continuous processing equipment.
2Ease of manufacture
If batch processing is used for preparing ester-based plasticizer, then the process is widely applied and relatively simple, but the reaction duration is long
Solution Approach 1:
The rapid decompression step creates a dynamic change that terminates the reaction quickly and facilitates immediate product discharge. This dynamic approach reduces reaction duration while keeping the batch process simple and equipment requirements minimal.
Solution Approach 2:
The patent uses rapid decompression to rush through the final stages of reaction and product separation in a single fast step, eliminating prolonged reaction times and multiple separation steps that would extend the overall process duration.
3Device complexity
If unoptimized batch process is used, then equipment requirements are simple, but energy consumption is high due to prolonged reaction and reflux
Solution Approach 1:
By changing to supercritical conditions and then rapidly decompressing, the process achieves high conversion rates faster, reducing the total energy input required. The simple equipment handles these parameter changes efficiently without requiring complex energy management systems.
Solution Approach 2:
The rapid decompression step rushes through the reaction completion and product separation phases quickly, minimizing the time energy must be maintained and reducing overall energy consumption while keeping equipment simple.
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 enhances reaction efficiency, minimizes reflux and energy consumption, and maximizes productivity by optimizing pressure control and catalyst use, ensuring high conversion rates and uniform product quality.
Implementation Method 1
pressure in the batch reactor is configured such that pressure at the early stage is 0.3 barg to 1.0 barg and pressure at the latter stage is 0 barg to 0.5 barg
Data Source
AI summary
The present invention provides a method for preparing an ester-based material, the method including a step in which in a batch reactor, under a catalyst, at least one polycarboxylic acid selected from the group consisting of a terephthalic acid, a phthalic acid, an isophthalic acid, a cyclohexane dicarboxylic acid, a cyclohexane tricarboxylic acid, a trimellitic acid, and citric acid reacts with at least one mono-alcohol having 3 to 12 alkyl carbon atoms, wherein pressure in the reactor is configured such that the pressure at the early stage is 0.3 barg to 1.0 barg and the pressure at the latter stage is 0 barg to 0.5 barg, the pressure at the early stage being greater than the pressure at the latter stage, and the early and latter stages are divided based on any one of the time points when reaction conversion rate is 30% to 90%.