Cyclohexane Oxidation Reactor with Titanium Silicate Catalyst
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Solution Overview
Problem
Current processes for oxidizing cyclohexane using a titanium silicate molecular sieve/H2O2 system face challenges such as high energy consumption, low yield, and difficulties in industrial-scale continuous production due to the need for solvents that increase separation complexity and costs.
Innovation Solution
A process involving the continuous oxidation of cyclohexane with an aqueous hydrogen peroxide solution and optional organic solvent, utilizing a titanium silicate molecular sieve catalyst, where the reaction is conducted under rectification conditions to harness latent heat for energy savings and facilitate product separation, thereby enhancing yield and reducing energy consumption.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If a large amount of solvent (30-90 wt%) is used in the oxidation reaction of cyclohexane with titanium silicate molecular sieve/H2O2 system, then the reaction effectiveness and selectivity to target product are improved, but the difficulty and cost of subsequent separation increase significantly
Solution Approach 1:
The patent extracts and removes the solvent from the reaction system by conducting the oxidation reaction without adding any solvent. The reactants (cyclohexane and H2O2) and catalyst (titanium silicate molecular sieve) are directly mixed to form a slurry that is fed into the reactor, eliminating the need for solvent recovery and separation steps.
Solution Approach 2:
The patent uses a slurry medium as an intermediary carrier to facilitate the reaction between cyclohexane and H2O2 in the absence of solvent. The slurry allows for effective contact between reactants and catalyst while maintaining manageable flow and heat transfer properties during the oxidation process.
2Manufacturing precision
If a large amount of solvent is used to achieve effective reaction, then the reaction selectivity is improved, but the energy consumption for heating and cooling increases
Solution Approach 1:
The patent removes the solvent component from the reaction system, thereby eliminating the energy requirements associated with heating and cooling large volumes of solvent. The reaction is conducted directly in the reactant mixture, significantly reducing thermal energy consumption.
Solution Approach 2:
The reaction mixture itself serves as the reaction medium without requiring external solvent addition. The system uses only the necessary components (cyclohexane, H2O2, and catalyst) to conduct the reaction, making the process self-sufficient and energy-efficient.
3Productivity
If conventional oxidation processes are used with solvent, then the reaction can proceed effectively, but the yield and productivity for continuous industrial production are limited
Solution Approach 1:
The patent implements a continuous oxidation process where the slurry mixture of cyclohexane, H2O2, and titanium silicate molecular sieve is continuously fed into the reactor, allowing for sustained productive operation. The reaction proceeds continuously without interruption, enhancing overall productivity and yield for industrial-scale production.
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
The process achieves higher selectivity and yield of cyclohexanone and cyclohexanol, while effectively utilizing reaction heat to minimize energy costs and simplify product separation, making it suitable for industrial application.
Implementation Method 1
using titanium silicate molecular sieve as a catalyst to prepare cyclohexanone (cyclohexanol)
Implementation Method 2
The oxidation of cyclohexane using hydrogen peroxide as an oxidizer
Implementation Method 3
discharging the unreacted cyclohexane and a part of water from the reaction zone top
Implementation Method 4
the reaction is intensively exothermic, which needs energy consumption for cooling the reaction
Data Source
Figure 1
AI summary
A process of oxidizing cyclohexane, comprising feeding cyclohexane, an aqueous hydrogen peroxide solution and optionally an organic solvent into a reaction zone through a feed inlet thereof under the oxidation reaction conditions for contact, and providing all or most of the oxidation product at the reaction zone bottom, wherein a part or all of the packing in the reaction zone is a titanium silicate molecular sieve-containing catalyst. The process of oxidizing cyclohexane according to the present invention carries out the oxidation in the reaction zone, which, firstly, utilizes the latent heat from reaction sufficiently so as to achieve energy-saving; secondly, increases the yield of target product and the availability of oxidizer; and thirdly, allows the separation of the oxidation product from the raw material cyclohexane as the reaction proceeds, such that the cost for subsequent separations can be saved.