Continuous Sulfonation Cyclization via High-Velocity Injection Vortex
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Solution Overview
Problem
The existing methods for synthesizing acesulfame potassium using sulfur trioxide as a sulfonating agent face issues with leakage due to its corrosive nature, leading to safety concerns and inefficient intermittent production, as they require stirring and specific reaction equipment, making continuous production unfeasible.
Innovation Solution
A process involving high-velocity injection of sulfonation raw material and sulfonating agent into a reactor to form a vortex, with a portion of the reaction mixture being cooled and recirculated, eliminating the need for stirring and specialized equipment, allowing for continuous production of the intermediate for acesulfame potassium synthesis.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of operation
If common reaction equipment with stirring device is used for sulfonation cyclization, then reaction can be promoted, but sulfur trioxide leakage occurs due to wear and tear on mechanical seal
Solution Approach 1:
The patent removes the stirring device from the reaction system entirely. Instead of using a stirring mechanism that creates mechanical seals prone to wear and sulfur trioxide leakage, the invention relies on the natural mixing capability of the vortex flow generated by high-velocity injection to achieve homogeneous reaction.
Solution Approach 2:
The patent replaces the mechanical stirring system with a fluid dynamic system. High-velocity injection creates a vortex that provides mixing through fluid motion rather than mechanical agitation, eliminating the need for mechanical seals and associated leakage problems.
2Reliability
If intermittent production is conducted with common equipment, then safety can be maintained, but production efficiency is low
Solution Approach 1:
The patent enables continuous production by eliminating the limitations of intermittent batch processing. The high-velocity injection system with vortex formation and recirculation allows the reaction to proceed continuously without interruption, maintaining safety while dramatically improving production efficiency.
3Temperature
If cooling brine is added into autoclave jacket during reaction, then reaction temperature can be controlled, but equipment complexity increases
Solution Approach 1:
The patent removes the external cooling jacket system from the autoclave. Instead of adding cooling brine through a complex jacket system, the invention extracts the temperature control function and achieves it through internal vortex formation and recirculation, which provides cooling through evaporative effects and heat distribution.
4Ease of manufacture
If sulfur trioxide is used as sulfonating agent, then strong sulfonating capability is achieved, but corrosiveness and oxidation risk increase
Solution Approach 1:
The patent uses high-velocity gas or liquid injection to create a vortex flow pattern. This pneumatic or hydraulic approach allows sulfur trioxide to be introduced and mixed in a controlled manner, reducing contact time with equipment surfaces and minimizing corrosive effects while maintaining effective sulfonation.
Solution Approach 2:
The continuous flow system ensures that sulfur trioxide is constantly moving through the reaction zone rather than being stagnant. This continuous action reduces the opportunity for corrosive attacks on equipment and minimizes oxidation risks by preventing localized accumulation of the aggressive agent.
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 approach prevents leakage and enables continuous production of the intermediate, enhancing productivity and safety by controlling temperature without the need for stirring devices and specialized equipment, thereby improving the efficiency and safety of the synthesis process.
Implementation Method 1
injecting a sulfonation raw material and a sulfonating reagent into a reactor at high velocity to form a vortex
Implementation Method 2
a cooling brine must be added into the jacket of autoclave during reaction to cool the heat discharged during reaction and control reaction temperature
Data Source
AI summary
The invention discloses a kind of sulfonation cyclization technique for synthesizing acesulfame potassium for continuous production without stirring and special equipment for this technique. An injection pump is adopted to directly inject the sulfonation raw material and sulfonating agent into autoclave for sulfonation cyclization reaction under high velocity. Moreover, the reciprocating pump is adopted to deliver part of materials in autoclave to condenser designed outside the autoclave for cooling, followed by delivering the cooled materials to another input end of injection pump which together with sulfonation raw material and sulfonating agent is injected into autoclave through high-velocity injection by injection pump. The apparatus is composed of autoclave, injection pump, reciprocating pump and condenser.