Continuous Xanthate Conversion With Water Contact Minimization
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Solution Overview
Problem
Existing xanthate production methods face issues with impurities, reduced yields and purities, high energy consumption, and inefficient temperature control, particularly in the solid and liquid processes, leading to suboptimal mineral processing performance.
Innovation Solution
A continuous production process utilizing three reactors, pumps, and heat exchangers to manage reactant feeds, including anhydrous alkali metal hydroxide and carbon disulfide, with controlled temperature and mixing to minimize impurities and maximize purity, using evaporative cooling and mechanical wiping to enhance efficiency.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If the solid process is used to produce xanthate, then the plant investment cost is reduced and no solvent storage equipment is required, but the heat transfer rates are reduced leading to reduced reactant feed rates and lower yields
Solution Approach 1:
The invention changes the physical state parameter from solid to liquid medium, enabling better heat transfer while maintaining cost advantages. The liquid process allows for improved heat transfer rates without requiring expensive chilling equipment, thus resolving the contradiction between investment cost and productivity.
2Device complexity
If the solid process is used to produce xanthate, then no drying equipment is required, but the localized temperatures at the reactant introduction site are higher leading to reduced yields and lower purities
Solution Approach 1:
The invention introduces a liquid organic medium as an intermediary substance that absorbs and distributes heat uniformly, preventing localized temperature spikes. This mediator allows the reaction to proceed without requiring complex drying equipment while maintaining high product purity through controlled temperature conditions.
3Manufacturing precision
If the liquid process is used to produce xanthate, then higher yields and purities are achieved, but drying, recovery, and purification equipment are required increasing costs and energy requirements
Solution Approach 1:
The invention optimizes the liquid process by changing the temperature parameter and using preheated reactants. This allows the reaction to proceed at temperatures where the liquid organic medium can be easily separated without requiring complex drying equipment, thus maintaining high purity while reducing equipment complexity and energy requirements.
4Quantity of substance
If water is present in the xanthate product, then the decomposition of xanthate into alcohol, carbon disulfide, carbonates, and trithiocarbonates is accelerated
Solution Approach 1:
The invention extracts and removes water from the reaction system using a liquid organic medium that is immiscible with water. The water is separated from the xanthate product through phase separation, preventing water-induced decomposition while maintaining the stability and effectiveness of the xanthate product.
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
Achieves xanthate products with greater than 95% purity and reduced energy consumption by maintaining steady-state operation and minimizing contact time with byproduct water, thereby improving the efficiency and effectiveness of mineral processing.
Implementation Method 1
The liquid process has the disadvantages of higher yields and purities as compared to the solid process. The liquid process has the disadvantages of requiring drying, recovery, and purification equipment and associated costs, also increased energy requirements associated with the drying and recovery process.
Implementation Method 2
The solid process has the disadvantages of the mixing equipment requires high power motors per unit of mixer volume necessitating smaller mixer volumes, reduced heat transfer rates between the reactants and the mixer shell or heat exchanger lead to reduced reactant feed rates
Data Source
AI summary
A method for the manufacture of high purity xanthate continuously in a system of reactors in a liquid organic medium by reacting caustic and alcohol to form alcoholate in a large circulating charge of previously reacted alcoholate at an elevated temperature, preferably no more than 110° C. A portion of the alcoholate is continuously withdrawn, cooled preferably to no more than 35° C. and rapidly dispersed with carbon disulfide to form xanthate in a large circulating charge of previously reacted xanthate while maintaining precise temperature control. Average contact time with byproduct water is 10 minutes. The product is continuously withdrawn and immediately dried to obtain in excess of 95% pure product.