Continuous Diester Production via Split Alcohol Feed
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Solution Overview
Problem
Current methods for producing diester-based materials, such as batch processes and continuous processes with reactor temperature control, face limitations in reducing steam volume and reflux, leading to high production costs and inefficiencies.
Innovation Solution
A continuous production method where dicarboxylic acid and primary alcohol are fed in a divided manner, with the primary alcohol split into front-end and rear-end feeds across multiple reaction units, controlling the amount and position of the rear-end feed to minimize steam volume and reflux.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Use of energy by moving object
If batch process or conventional continuous process with single feed is used, then production simplicity is maintained, but steam volume and reflux are excessive leading to high energy consumption
Solution Approach 1:
The feed system is segmented into multiple feed points along the reaction path. Primary alcohol is fed at different positions (first feed point before esterification reactor, second feed point before trans-esterification reactor) to control reaction conditions and minimize steam requirements at each stage, directly resolving the contradiction between energy efficiency and system simplicity
Solution Approach 2:
Primary alcohol is fed in advance at the first feed point before entering the esterification reactor, allowing the reaction to proceed with optimal reactant concentration. This preliminary feeding action enables better reaction efficiency and reduces the need for excessive steam, addressing the energy consumption issue while maintaining manageable system complexity
2Productivity
If batch process or conventional continuous process is used, then process simplicity is maintained, but productivity is low
Solution Approach 1:
The reaction system is divided into multiple reaction stages (esterification reactor, trans-esterification reactor) with separate feed points for primary alcohol. This segmentation allows continuous operation at each stage, significantly improving productivity while the modular structure keeps the overall system complexity manageable
Solution Approach 2:
The process employs continuous feeding of primary alcohol at multiple points throughout the reaction sequence, maintaining constant reactant supply and preventing idle time. This continuous action dramatically improves production efficiency compared to batch processes, while the systematic arrangement of feed points and reactors keeps the system design organized and manageable
3Manufacturing precision
If excessive primary alcohol is fed at once, then conversion rate is improved, but reflux increases leading to waste of substance
Solution Approach 1:
The primary alcohol feed is segmented into multiple portions delivered at different locations along the reaction path. This prevents the formation of excessive unreacted alcohol that would cause reflux, while still achieving high conversion rates through optimized local concentration at each reaction stage, thus resolving the contradiction between conversion efficiency and substance loss
Solution Approach 2:
Different feed rates and positions of primary alcohol are applied to match the specific requirements of each reaction stage. The first feed point provides optimal concentration for esterification, while the second feed point supplements the trans-esterification reaction. This localized optimization achieves high conversion without generating excessive reflux, addressing both conversion rate and substance loss concerns
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 significantly reduces the volume of steam required and the amount of reflux, enhancing the cost competitiveness of the final product by optimizing energy use and conversion rates.
Implementation Method 1
an esterification reactor (11) in which a direct esterification reaction is performed
Implementation Method 2
a trans-esterification reactor (21) in which a trans-esterification reaction is performed
Implementation Method 3
a separator (12) in which gas-liquid separation is performed
Data Source
AI summary
The present disclosure relates to a continuous production method of a diester-based material in a continuous production process comprising a reaction part in which a total of N reaction units from a first reaction unit to an N-th reaction unit are connected in series. The method comprising the step of feeding dicarboxylic acid and a primary alcohol, wherein the feed of the primary alcohol is divided into front-end feed of being fed into a first reaction unit and rear-end feed of being fed into one or more reaction units selected among from a second reaction unit to an N-th reaction unit, wherein the amount of the rear-end feed is 5 to 80 wt % based on the total feed amount of the primary alcohol into a reaction part, and the N is an integer of 3 to 6. According to the present invention, it is possible to ensure the ease of process operation through reducing the amount of reflux compared to a typical batch process and reducing the volume of steam for heating a reactor, and to ensure the economic feasibility of a product through saving energy.