1,3-Butylene Glycol Purification With Catalyst Deactivation
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Solution Overview
Problem
Conventional methods fail to effectively reduce hydrogenation/dehydrogenation catalyst residues below 100 ppm in crude 1,3-butylene glycol, leading to catalytic decomposition and the formation of undesirable by-products during purification, which adversely impact product quality, especially for cosmetic-grade applications.
Innovation Solution
A process involving catalyst removal or deactivation to reduce active hydrogenation/dehydrogenation catalyst levels to less than 100 ppm in the crude 1,3-butylene glycol stream, followed by distillation, using a combination of filtration and deactivation systems to minimize by-product formation.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If conventional filtration and settling procedures are used to remove catalyst, then the process is simple and easy to operate, but the catalyst residue remains above 100 ppm causing by-product formation
Solution Approach 1:
The patent extracts and removes the harmful catalyst residue from the crude 1,3-butylene glycol stream through advanced filtration systems and deactivation treatments, reducing catalyst levels below 100 ppm to prevent by-product formation during distillation
Solution Approach 2:
The patent introduces intermediary substances or treatments (such as deactivation agents or advanced filter media) that facilitate the removal or neutralization of catalyst residues, enabling effective purification without requiring overly complex processing systems
2Productivity
If catalyst residue is not effectively removed, then the purification process is simpler, but by-products such as 2-propanol, 2-butanol, and 4-hydroxy-2-butanone form during distillation
Solution Approach 1:
The patent applies preliminary catalyst removal and deactivation treatments to the crude 1,3-butylene glycol before distillation, preventing the formation of by-products during the subsequent purification process and ensuring high product purity
Solution Approach 2:
The patent applies preliminary anti-action by deactivating or removing the catalyst before the distillation process, thereby preventing the harmful catalytic decomposition that would otherwise occur during heating and produce unwanted by-products
3Manufacturing precision
If advanced catalyst removal methods are used, then by-product formation is minimized, but the process complexity and cost increase
Solution Approach 1:
The patent replaces simple mechanical filtration with more advanced removal mechanisms including chemical deactivation treatments and sophisticated filtration systems, achieving catalyst residue levels below 100 ppm through a combination of methods rather than relying on a single complex system
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
Significantly reduces the formation of by-products such as 2-propanol, 2-butanol, and 4-hydroxy-2-butanone, enhancing the purity and odor quality of the final 1,3-butylene glycol product, suitable for cosmetic applications.
Implementation Method 1
hydrogenating the acetaldol in the presence of a hydrogenation/dehydrogenation catalyst in a hydrogenating reactor to produce a crude 1,3-butylene glycol stream
Implementation Method 2
in the presence of a hydrogenation/dehydrogenation catalyst
Implementation Method 3
conventional catalyst removal procedures like settling and filtration
Implementation Method 4
distilling the crude mixture
Data Source
AI summary
Disclosed is an improved method of making low-impurity 1,3-butylene glycol includes: (a) aldolizing acetaldehyde in a reactor to produce acetaldol; (b) hydrogenating the acetaldol in the presence of a hydrogenation/dehydrogenation catalyst in a hydrogenating reactor to produce a crude 1,3-butylene glycol stream with an active hydrogenation/dehydrogenation catalyst content; (c) removing or deactivating catalyst in the crude 1,3-butylene glycol stream; and (d) distilling the treated crude 1,3-butylene glycol stream in a distillation train to provide a purified 1,3-butylene glycol product.