Chlorinated C3-6 Alkane Production via Segmented Telomerisation
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Solution Overview
Problem
The production of high purity chlorinated C3-6 alkane compounds is challenging due to the presence of impurities that reduce yield and catalyst effectiveness in industrial processes, especially in continuous processes where impurities are difficult to separate and can poison catalysts.
Innovation Solution
A process involving a telomerisation reaction between carbon tetrachloride and an alkene in a principal alkylation zone, with controlled molar ratios and additional steps such as dealkenation and aqueous treatment to minimize impurity formation and maximize purity and selectivity.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If chlorinated alkanes are produced using multi-step continuous processes, then industrially acceptable product volumes are achieved, but cumulative side reactions generate unacceptable impurities
Solution Approach 1:
The process is divided into a first alkylation zone and a second alkylation zone, each performing a specific function. The first zone conducts the primary telomerisation reaction at controlled conversion levels, while the second zone completes the reaction and removes impurities. This segmentation allows each zone to be optimized independently, maintaining high productivity while achieving high purity through the specialized function of the second zone.
Solution Approach 2:
The reaction mixture acts as an intermediary carrier between the two alkylation zones. It transports the telomerisation products from the first zone to the second zone, where impurities are removed. This intermediary role allows the system to maintain continuous operation while achieving purification, resolving the contradiction between productivity and purity.
2Manufacturing precision
If intensive distillation steps are used to remove impurities, then product purity is improved, but energy consumption increases and catalyst life is compromised
Solution Approach 1:
The second alkylation zone performs preliminary purification of the reaction mixture before final product isolation. By removing impurities at this intermediate stage through controlled chemical reactions rather than intensive distillation, the process reduces subsequent energy requirements and protects catalysts from poisoning, while still achieving the required final product purity.
3Productivity
If conversion of carbon tetrachloride is increased to improve yield, then productivity increases, but side reactions increase generating more impurities
Solution Approach 1:
The conversion process is segmented into two zones with different conversion targets. The first zone operates at controlled, lower conversion levels to minimize side reactions and impurity formation. The second zone then completes the conversion and removes the impurities generated. This segmentation allows the system to achieve high overall yield while controlling impurity generation at each stage.
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 process improves efficiency, reduces energy consumption, and achieves high selectivity and yield of high purity chlorinated C3-6 alkane compounds by controlling the reaction conditions and incorporating steps to manage impurities effectively.
Implementation Method 1
A process involving a telomerisation reaction between carbon tetrachloride and an alkene in a principal alkylation zone
Implementation Method 2
extracting a portion of the reaction mixture from the principal alkylation zone
Implementation Method 3
incorporating steps to manage impurities effectively
Data Source
AI summary
Disclosed is a process for producing a chlorinated C3-6 alkane comprising providing a reaction mixture comprising an alkene and carbon tetrachloride in a principal alkylation zone to produce chlorinated C3-6 alkane in the reaction mixture, and extracting a portion of the reaction mixture from the principal alkylation zone, wherein:a) the concentration of the chlorinated C3-6 alkane in the reaction mixture in the principal alkylation zone is maintained at a level such that the molar ratio of chlorinated C3-6 alkane:carbon tetrachloride in the reaction mixture extracted from the alkylation zone does not exceed 95:5 when the principal alkylation zone is in continuous operation; and/orb) the reaction mixture extracted from the principal alkylation zone additionally comprises alkene and the reaction mixture is subjected to a dealkenation step in which at least about 50% or more by weight of the alkene present in the reaction mixture is extracted therefrom and at least about 50% of the extracted alkene is fed back into the reaction mixture provided in the principal alkylation zone; and/orc) the reaction mixture present in the principal alkylation zone and extracted from the principal alkylation zone additionally comprises a catalyst, and the reaction mixture extracted from the principal alkylation zone is subjected to an aqueous treatment step in which the reaction mixture is contacted with an aqueous medium in an aqueous treatment zone, a biphasic mixture is formed and an organic phase comprising catalyst is extracted from the biphasic mixture.