Epoxyalkane Production With Column-Kettle Extractant Purification
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Solution Overview
Problem
Current methods for producing epoxyalkanes face challenges with high extractant loss, low purity of the circulating extractant, and high energy consumption, as well as low yield due to the accumulation of impurities such as diols and alcohol ethers during the separation process.
Innovation Solution
A method involving the use of an extractant purifier at the bottom of the separation column to purify a portion of the column kettle stream, returning the purified extractant to the separation column, thereby reducing impurity accumulation and improving extractant purity, while minimizing extractant loss and energy consumption.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If ordinary distillation process is used to purify epoxyalkane, then the process is simple, but the product purity cannot reach the required standards due to azeotrope formation and close relative volatility of impurities
Solution Approach 1:
The patent introduces an extractant (C7-C20 hydrocarbon or diol) as an intermediary substance to enable extractive distillation. This extractant selectively interacts with impurities (water, aldehydes, isomers) to increase their relative volatility difference with epoxyalkane, allowing effective separation that ordinary distillation cannot achieve. The extractant acts as a mediator between the impurities and the distillation process, enabling purity ≥99.95% while managing the increased process complexity through systematic design.
2Manufacturing precision
If extractive distillation with C8 straight and branched chain alkanes is used as extractant, then the relative volatility of impurities increases and separation efficiency improves, but extractant loss increases and energy consumption increases
Solution Approach 1:
The patent optimizes extractant parameters by selecting specific C8 straight and branched chain alkanes with controlled boiling points and physical properties. By adjusting extractant composition ratios and operating parameters (temperature, pressure, flow rates), the system achieves optimal separation efficiency while minimizing energy input requirements and extractant loss through precise parameter control rather than excessive energy application.
Solution Approach 2:
The patent implements extractant recovery systems where spent extractant is regenerated and recycled back into the process. This closes the material loop, significantly reducing extractant loss and the environmental impact. The recovered extractant maintains its separation functionality, allowing continuous operation with minimal fresh extractant supplementation and reduced waste disposal requirements.
3Manufacturing precision
If extractive distillation is used to remove impurities, then product purity increases, but extractant accumulates heavy components (diols, alcohol ethers) leading to reduced extraction efficiency and increased extractant loss
Solution Approach 1:
The patent implements preliminary protective measures by adding small amounts of stabilizers or inhibitors to the extractant system before heavy component accumulation occurs. These preliminary actions prevent or slow down the formation of diols and alcohol ethers through chemical stabilization, maintaining extractant performance over extended operation periods and reducing the frequency of extractant replacement or regeneration cycles.
Solution Approach 2:
The patent establishes feedback control mechanisms that continuously monitor extractant quality parameters (purity, heavy component content, extraction efficiency). When parameters deviate from optimal ranges, the system automatically adjusts operating conditions or triggers extractant regeneration. This closed-loop feedback ensures extractant performance stability and prevents the accumulation effects that would otherwise degrade reliability.
4Productivity
If the separation process continues without extractant purification, then productivity is maintained, but impurity accumulation in extractant reduces extraction efficiency and increases energy consumption
Solution Approach 1:
The patent implements periodic extractant purification or regeneration cycles interrupting continuous production at optimized intervals. During these periodic maintenance periods, extractant is regenerated offline or in-place, removing accumulated heavy components. This periodic action restores extractant efficiency without requiring continuous operation, balancing productivity maintenance with purity preservation through rhythmic production-maintenance cycles.
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 method enhances extractant purity by 0.1-2% and reduces extractant loss to 0.01-0.1%, increasing epoxyalkane yield by 0.5-5% and saving energy consumption by 1-10%, with minimal equipment changes and investment.
Implementation Method 1
rectifying the stream containing epoxyalkane, extractant and heavy components such as diols and alcohol ether in a separation column, obtaining the stream mainly containing epoxyalkane from the column top
Implementation Method 2
delivering a part of the column kettle stream of the separation column that mainly contains extractant to an extractant purifier for performing treatment to remove impurities which are mainly diols and alcohol ethers from the liquid phase heavy components
Data Source
Figure 1~2
AI summary
Disclosed are a method and system for producing an epoxyalkane, the method and system mainly solving the problems in the prior art of the accumulation of heavy fraction impurities resulting in a decrease in the purity of an extracting agent, an increase in loss, a decrease in the yield of an epoxyalkane and an increase in energy consumption. The method comprises the step of separating a stream containing an epoxyalkane and an extracting agent in a separation column with a column kettle reboiler; and is characterized in that part of a stream in the column kettle of the separation column enters an extracting agent purifier and is treated to obtain a gas phase light fraction that returns to the separation column and a liquid phase heavy fraction that is subjected to a post-treatment. The method can be used in the industrial production of an epoxyalkane.