Supercritical CO2 Esterification of Carboxylic Acids

Resolve Bottlenecks,
Find Innovative SolutionsGenerate Solutions

Solution Overview

Problem

Current methods for recovering carboxylic acids from fermentation broths are costly and inefficient, involving multiple steps and generating significant waste due to the need for salt formation and subsequent neutralization, which increases processing costs and environmental impact.

Innovation Solution

A process that converts carboxylic acids from fermentation broths into their corresponding esters under supercritical or critical conditions using a CO2 atmosphere without additional acid catalysts, allowing for easier recovery and recycling of by-products, thereby simplifying downstream processing and reducing waste.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Temperature

If calcium carbonate is used to maintain pH during fermentation, then the pH is maintained effectively, but calcium sulfate waste is generated that requires disposal

Engineering Contradiction:

ImprovepH maintenanceVSAvoidcalcium sulfate waste

Core Design Contradiction:

TemperatureVSLoss of substance

Solution Approach 1:

The patent changes the cation parameter from calcium to magnesium, which fundamentally alters the downstream processing requirements. Magnesium salts remain soluble and do not require acid neutralization, eliminating the calcium sulfate waste disposal problem while maintaining effective pH control during fermentation

Inventive Principle:

Principle #35Parameter changes

Solution Approach 2:

The patent converts the potential harm of magnesium salts (which were previously considered problematic due to solubility issues) into a benefit by utilizing their solubility to avoid precipitation and waste generation. The magnesium salts remain in solution and can be directly processed without additional neutralization steps, turning a potential disadvantage into a process advantage

Inventive Principle:

Principle #22Blessing in disguise (Convert harm into benefit)

2Reliability

If multiple processing steps are used for acid recovery, then the recovery is thorough, but the processing cost increases

Engineering Contradiction:

Improveacid recovery completenessVSAvoidprocessing cost

Core Design Contradiction:

ReliabilityVSEase of manufacture

Solution Approach 1:

The patent extracts and eliminates the unnecessary salt formation and neutralization steps from the traditional acid recovery process. By using magnesium-based pH maintenance, the process directly yields free carboxylic acids without requiring conversion to calcium salts and subsequent acid treatment, thereby reducing processing steps and costs while maintaining recovery completeness

Inventive Principle:

Principle #2Taking out (Extraction)

Solution Approach 2:

The patent enables a continuous process where magnesium compounds maintain pH during fermentation and the resulting magnesium salts are directly converted to free acids through a single step, eliminating the discontinuous batch processing of salt formation, filtration, and neutralization required in traditional methods, thereby reducing overall processing time and cost

Inventive Principle:

Principle #20Continuity of useful action

3Reliability

If traditional salt formation method is used, then the acid is recovered, but energy consumption increases due to multiple processing steps

Engineering Contradiction:

Improveacid recoveryVSAvoidenergy consumption

Core Design Contradiction:

ReliabilityVSUse of energy by moving object

Solution Approach 1:

The patent removes the energy-intensive salt formation and neutralization steps from the acid recovery process. By using magnesium compounds that maintain pH and produce soluble salts, the process eliminates the need for repeated heating, cooling, and filtration cycles associated with traditional calcium salt methods, thereby reducing energy consumption while maintaining acid recovery effectiveness

Inventive Principle:

Principle #2Taking out (Extraction)

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 the efficiency and cost-effectiveness of carboxylic acid recovery by eliminating the need for salt formation and neutralization, allowing for direct conversion to esters that can be easily processed, reducing energy consumption and waste generation.

Implementation Method 1

A process that converts carboxylic acids from fermentation broths into their corresponding esters under supercritical or critical conditions using a CO2 atmosphere

Methodology Applied

Scientific EffectSupercritical fluid: Supercritical Fluid

Data Source

PatentUS9834531B2Use of carboxylic acids and furanic molecules for esterification

Publication Date: 2017.12.05 ARCHER DANIELS MIDLAND CO

AI summary

A process for recovering and using an organic/carboxylic acid or furanic molecule by means of making an ester of a free carboxylic acid or furanic molecule with an alcohol in carbon dioxide (CO2) without the presence of any other acid catalyst at a reaction temperature and pressure that corresponds to supercritical, critical or near critical conditions for the alcohol and/or CO2 is described. The process can constitute part of a general process of refining carboxylic acids derived from a fermentation broth or use in the production of a variety of chemical compounds, such as C4 platform compounds or polymers.