Direct Ester Conversion to Calcium Carboxylates
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Solution Overview
Problem
Current methods for producing calcium carboxylates are energy-intensive, generate significant waste, and result in low yields, necessitating the development of more efficient processes for their production.
Innovation Solution
A method involving the reaction of water and calcium oxide with esters or anhydrides, followed by heating to remove co-products and neutralizing the solution to produce calcium carboxylates in solid form, optimizing the molar ratios of reactants and reaction conditions to enhance yield and reduce waste.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If conventional methods (reacting carbonate, hydroxide, or oxide with concentrated or dilute carboxylic acid) are used to produce calcium carboxylates, then the production process is well-established and straightforward, but the process is energy-intensive, generates significant waste, and results in low yields
Solution Approach 1:
The invention changes the reaction parameters by using esters instead of concentrated or dilute carboxylic acids, and by controlling the molar ratio of calcium oxide to ester (excess calcium oxide). This parameter change transforms the reaction pathway to achieve higher yields and reduced energy consumption while maintaining process simplicity
Solution Approach 2:
The invention converts the traditionally harmful byproduct methanol (from ester hydrolysis) into a removable co-product that can be easily separated by heating. The reaction conditions are optimized so that methanol evaporates during the reaction or subsequent heating, turning a potential waste problem into a simplified separation advantage
2Reliability
If conventional methods are used to produce calcium carboxylates, then the process is established, but energy consumption is high
Solution Approach 1:
The invention maintains continuous useful action by performing the reaction in a single step where calcium oxide reacts with ester to directly form calcium carboxylate and methanol. The methanol is simultaneously removed by heating or evaporation during the reaction, eliminating the need for separate energy-intensive purification steps required by conventional methods
Solution Approach 2:
The reaction system performs self-service by using the heat generated from the exothermic reaction and subsequent heating to evaporate the methanol co-product. The process is designed so that the reaction conditions themselves facilitate the removal of byproducts, reducing external energy input requirements
3Ease of manufacture
If conventional methods are used to produce calcium carboxylates, then the process is traditional and well-documented, but waste generation is significant
Solution Approach 1:
The invention extracts the harmful byproduct (methanol) from the reaction system by designing the process to generate it in a form that can be easily removed through heating or evaporation. This extraction principle separates the desired product (calcium carboxylate) from the waste (methanol) efficiently, minimizing waste generation while maintaining process familiarity
Solution Approach 2:
The invention implements discarding and recovering by removing methanol from the reaction mixture through heating or evaporation. The methanol is discarded as a vapor or can be condensed and recovered for reuse, while the calcium carboxylate remains in the reaction mixture as the desired product, significantly reducing waste
4Ease of manufacture
If conventional methods are used to produce calcium carboxylates, then the methodology is standard, but yields are low
Solution Approach 1:
The invention applies partial or excessive action by using an excess of calcium oxide (molar ratio of calcium oxide to ester greater than 0.5:1, preferably 1:1 or higher). This excessive action ensures complete conversion of the ester to calcium carboxylate, driving the reaction to completion and achieving high yields while maintaining standardized procedural simplicity
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 process achieves high yields of calcium carboxylates with minimal waste and energy consumption, allowing for the production of high-purity products like calcium propionate and acetate, addressing the inefficiencies of traditional methods.
Implementation Method 1
reacting water and calcium oxide to obtain a slurry
Implementation Method 2
reacting the slurry with methyl propionate, wherein the calcium oxide is reacted in a molar excess compared to the methyl propionate, to obtain a reaction solution
Implementation Method 3
heating the reaction solution to remove an amount of methanol from the reaction solution
Implementation Method 4
neutralizing the reaction solution to a pH of from 7.0 to 9.5 by adding a sufficient quantity of propionic acid
Implementation Method 5
filtering the reaction solution
Data Source
AI summary
A calcium carboxylate is prepared by reacting water, calcium oxide, and a compound of formula (I):wherein R is a C1-C3 alkyl and R1 is a C1 or C2 alkyl. The reaction solution is heated to remove an amount of a co-product from the reaction solution. The calcium carboxylate may be recovered in a solid form from the reaction solution.