Bisphenol A Production Process with Pressurized Separation
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Solution Overview
Problem
The existing production process for bisphenol A suffers from inefficiencies such as high energy consumption, low solid-liquid separation efficiency, and excessive material backmixing, leading to reduced purity and increased energy costs.
Innovation Solution
The process involves arranging an external circulation heat exchanger, a light component removing tank, a pressurized separating unit, a double-effect falling film evaporator, and an isomerization reactor, while optimizing the trend of recycling streams and increasing heat exchange between process streams.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If traditional crystallization and solid-liquid separation methods are used, then bisphenol A can be produced, but energy consumption is high and separation efficiency is low
Solution Approach 1:
The patent applies parameter changes by utilizing pressure differential as the driving force for solid-liquid separation instead of traditional gravity-based filtration. The pressurized separating unit operates at pressures above atmospheric pressure, enabling faster filtration rates and improved separation efficiency while reducing the need for energy-intensive heating and multiple washing cycles
Solution Approach 2:
The patent extracts the solid-liquid separation step from the traditional crystallization process and performs it in a dedicated pressurized separating unit. This allows for more efficient separation of bisphenol A crystals from the mother liquor, reducing energy consumption associated with traditional filtration and washing methods
2Manufacturing precision
If excessive material backmixing occurs in the reaction system, then reaction equilibrium is affected, but purity of bisphenol A is reduced
Solution Approach 1:
The patent segments the reaction system into distinct zones with controlled flow patterns. By organizing reactors and separation units in a sequential arrangement with minimized backmixing, the process maintains better compositional stability and achieves higher purity bisphenol A production
3Use of energy by moving object
If conventional heat exchange arrangements are used, then process simplicity is maintained, but energy consumption increases
Solution Approach 1:
The patent implements preliminary heat exchange actions by preheating feed streams using heat recovered from process streams before they enter the pressurized separating unit. This preliminary heat recovery reduces the overall energy consumption of the process while the integrated heat exchange arrangement manages the added complexity
Data Source
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AI summary
The present invention relates to a production process and device for synthesizing bisphenol A by a resin method, including a condensation reaction unit for performing a catalytic condensation reaction between phenol and acetone to generate bisphenol A, a first-stage adduct crystallization unit for mixing a concentrated solution with adduct crystals recycled after melting and then performing adduct crystallization, a liquid-phase dephenolization unit for melting an adduct to yield a bisphenol A product, a secondary adduct crystallization unit for recycling phenol and bisphenol A from a mother solution, a solvent recycling unit for recycling unreacted phenol and unreacted acetone, and discharging phenol-containing process water for sewage treatment, and a cracking and rearrangement unit for recycling the phenol from the mother solution, and convert bisphenol A, 2,4-bisphenol A and the like therein in the mother solution into the bisphenol A.