Semi-Continuous Ester Production via Parallel Batch Reactors
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Solution Overview
Problem
Existing methods for preparing ester-based compositions using batch reactors are inefficient and lack stability due to the batch nature of the process and inadequate pressure control.
Innovation Solution
A method involving a plurality of batch reactors connected in parallel, operated semi-continuously with controlled pressure, where a polycarboxylic acid and a mono-alcohol are sequentially fed into the reactors to ensure efficient and stable esterification reactions.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If batch reactors are used for esterification reaction, then the stability of the reaction process is maintained, but the productivity is low due to the batch nature of the process
Solution Approach 1:
The batch reaction process is segmented into multiple stages by dividing the reaction into several batch reactors operating in sequence. Each reactor handles a specific stage of the reaction, allowing the system to maintain batch reactor stability while achieving semi-continuous operation and improved overall productivity through parallel processing capabilities.
Solution Approach 2:
The patent implements semi-continuous operation by sequentially feeding reaction mixture into multiple batch reactors. This allows the reaction process to continue without interruption across multiple reactor units, transforming the traditional intermittent batch process into a more continuous operation that maintains stability while enhancing productivity.
2Ease of operation
If pressure is not controlled during esterification reaction, then the process is simple to operate, but the reaction efficiency and product quality are poor
Solution Approach 1:
The patent applies pressure control as a key parameter change to optimize the esterification reaction. By controlling pressure at different stages of the reaction process, the system improves reaction efficiency and product quality while maintaining ease of operation through systematic pressure management rather than complex procedural changes.
3Productivity
If multiple batch reactors are operated in parallel with pressure control, then the productivity is improved, but the device complexity increases
Solution Approach 1:
The system divides the production process into multiple batch reactors operating in parallel, with each reactor handling a specific portion of the total production. This segmentation allows the system to scale productivity by adding reactors while managing complexity through standardized, modular reactor units with consistent pressure control systems.
Solution Approach 2:
The batch reactors are designed as universal, multi-functional units that can perform the same esterification reaction under controlled pressure conditions. This universality reduces device complexity by using identical standardized equipment rather than custom-designed reactors for each stage, making the system easier to operate and maintain while achieving high productivity.
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 achieves efficient and stable production of ester-based compositions by maintaining the stability of batch reactors and enhancing the efficiency of the semi-continuous process through controlled pressure management.
Implementation Method 1
putting a polycarboxylic acid and a mono-alcohol having 3 to 12 alkyl carbon atoms into a mixer to form a reaction mixture; sequentially putting the reaction mixture into N batch reactors to perform a reaction
Implementation Method 2
pressures of the N reactors are each independently configured such that the pressure at the early stage is 0.3 barg to 1.0 barg and the pressure at the latter stage is 0 barg to 0.5 barg
Data Source
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AI summary
The present invention relates to a method for preparing an ester-based composition, the method configured to sequentially operate a plurality of batch reactors and control pressure in each reactor, and the ester-based composition is semi-continuously prepared to have high productivity as well as stability of the batch reactors.