Heterogeneous Catalyst Synthesis of Cyclocarbonates at Atmospheric Pressure
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Solution Overview
Problem
Existing methods for synthesizing cyclocarbonates are hindered by high energy consumption, toxicity of monomeric isocyanates, and the need for costly protective measures, as well as issues with moisture sensitivity and migration of isocyanates in two-component polyurethane adhesives, and current heterogeneous catalysts are not commercially available.
Innovation Solution
A heterogeneous catalyst system comprising an alkali metal halide, such as sodium iodide or lithium bromide, combined with silica as a solid support, is used to catalyze the reaction of epoxy compounds with carbon dioxide at atmospheric pressure and elevated temperature, significantly improving conversion rates and times.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If high pressure conditions are used for synthesizing cyclocarbonates, then conversion rate is improved, but energy consumption increases and equipment complexity increases
Solution Approach 1:
The patent changes the pressure parameter from high pressure to atmospheric pressure, and adjusts temperature parameters (100-150°C) to achieve optimal conversion rates without the energy consumption and equipment complexity associated with high pressure conditions
Solution Approach 2:
The patent uses a composite heterogeneous catalyst system combining alkali metal halide (NaI, KI, LiBr) with silica gel or molecular sieves, creating a composite material that achieves high conversion rates at atmospheric pressure, resolving the contradiction between conversion rate and pressure requirements
2Productivity
If homogeneous catalyst is used for cyclocarbonate synthesis, then conversion rate is improved, but catalyst separation complexity increases
Solution Approach 1:
The patent employs porous materials such as silica gel and molecular sieves as catalyst supports, creating a heterogeneous catalyst system where the active alkali metal halide species are trapped within the porous structure, enabling easy separation by simple filtration while maintaining high conversion rates
Solution Approach 2:
The patent creates a composite heterogeneous catalyst combining alkali metal halide with silica gel or molecular sieves, where the composite structure provides both catalytic activity and ease of separation, resolving the contradiction between conversion rate and separation complexity
3Speed
If reaction temperature is increased, then reaction speed is improved, but energy consumption increases
Solution Approach 1:
The patent optimizes the temperature parameter to a moderate range (100-150°C) and combines it with atmospheric pressure conditions and a specialized heterogeneous catalyst system, achieving fast reaction rates without the excessive energy consumption that would result from higher temperatures alone
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 enables efficient and cost-effective synthesis of cyclocarbonates with reduced environmental impact and eliminates the need for costly protective measures, as the catalysts are easily separable and recoverable, and the process occurs at lower temperatures and pressures compared to existing methods.
Implementation Method 1
a heterogeneous catalyst system comprising an alkali metal halide and silica as well as the use of said catalyst system for the synthesis of cyclocarbonates
Data Source
AI summary
The present invention relates to a method for synthesizing cyclocarbonates by reacting an epoxy compound and carbon dioxide at atmospheric pressure and elevated temperature in the presence of a heterogeneous catalyst system comprising an alkali metal halide and silica as well as the use of said catalyst system for the synthesis of cyclocarbonates.