Dialkyl Malonate Ester Production via Fermentation Broth Acidification
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Solution Overview
Problem
Fermentation processes for producing organic molecules often require additional purification steps to isolate specific reactants, which increases time and costs, making it desirable to find methods for quickly and efficiently producing fermentation products as reactants.
Innovation Solution
A method for producing dialkyl malonate esters involves acidifying a malonate composition containing at least 30 wt % malonic acid equivalents, contacting it with an organic alcohol and inorganic acid to solubilize and form a first acidified malonate composition, separating a precipitate, and optionally heating to form the dialkyl malonate ester, followed by distillation to isolate a distillate comprising greater than 90 wt % dialkyl malonate ester.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If additional purification steps are taken to isolate specific reactants from fermentation processes, then the purity of reactants is improved, but the time and costs increase
Solution Approach 1:
The patent performs preliminary acidification of the fermentation broth to convert malonate salts into malonic acid before esterification. This preliminary action simplifies subsequent purification steps and enables direct use of fermentation products as reactants, reducing both time and cost while maintaining high purity
Solution Approach 2:
The patent extracts and utilizes malonic acid directly from the fermentation broth through acidification, eliminating the need for complex isolation and purification steps. The malonic acid is taken out in a form ready for esterification, reducing processing time and costs
2Manufacturing precision
If additional purification steps are taken to isolate specific reactants from fermentation processes, then the purity of reactants is improved, but the costs increase
Solution Approach 1:
The patent performs preliminary acidification of the fermentation broth to convert malonate salts into malonic acid before esterification. This preliminary action simplifies subsequent purification steps and enables direct use of fermentation products as reactants, reducing both time and cost while maintaining high purity
Solution Approach 2:
The fermentation broth itself serves as the starting material after simple acidification, eliminating the need for expensive external purification processes. The system uses its own output (fermentation broth) as input for the next stage with minimal intermediate processing
3Productivity
If fermentation products are used directly as reactants without additional purification, then the time and costs are reduced, but the complexity of handling mixed compositions increases
Solution Approach 1:
The patent changes the pH parameter of the fermentation broth through acidification, converting malonate salts into malonic acid. This parameter change simplifies the composition and enables direct esterification, maintaining high productivity while reducing handling complexity
Solution Approach 2:
The acidification process induces a chemical phase transition from malonate salts to malonic acid, changing the solubility and reactivity characteristics of the fermentation products. This enables straightforward extraction and esterification without complex separation procedures
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 allows for the efficient production of high-purity dialkyl malonate esters, reducing the need for additional purification steps and optimizing the use of fermentation products as reactants, thereby streamlining the production process and reducing costs.
Implementation Method 1
acidifying the malonate composition comprises contacting an organic alcohol and an inorganic acid with the malonate composition to solubilize the malonate composition
Implementation Method 2
contacting an organic alcohol and an inorganic acid with the malonate composition to solubilize the malonate composition to form a first acidified malonate composition
Implementation Method 3
The method further includes optionally heating the malonate composition, the first acidified malonate composition, or both, to form the dialkyl malonate ester
Implementation Method 4
step c) which includes distilling the product of step b) to isolate a distillate comprising the dialkyl malonate ester
Data Source
AI summary
The present disclosure relates to a method for making a dialkyl malonate ester, including a) acidifying a malonate composition comprising:at least 30 wt % based on malonic acid equivalents of a compound of formula I:where M+ is a Group I alkali metal cation or ammonium cation. The malonate composition optionally includes:a compound of formula II:and/ormalonic acid. Step a) comprises contacting an organic alcohol and an inorganic acid with the malonate composition to form a first acidified malonate composition comprising:a compound of formula IV:a compound of formula V:and/ormalonic acid. R1 and R2 are independently (C1-C8)alkyl.