Integrated Reactor for Ester Composition Production
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Solution Overview
Problem
Current methods for preparing ester compositions are inefficient, require extensive facility space, and involve redundant equipment and transfer processes, particularly in the production of terephthalate-based plasticizers, which are needed as alternatives to phthalate-based plasticizers due to environmental concerns.
Innovation Solution
An integrated reactor system that combines direct esterification and trans-esterification processes in a single space, along with a gas-liquid separation column, purification unit, alcohol storage tank, and mixed alcohol separation column, allowing for sequential reactions and efficient separation and recirculation of alcohols, thereby reducing facility space and transfer time.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If separate reactors and equipment are used for direct esterification and trans-esterification processes, then each reaction can be optimized independently, but facility space increases and transfer time between processes extends
Solution Approach 1:
The patent combines the direct esterification reactor and trans-esterification reactor into a single integrated reactor system. The reactor includes a first reaction space for direct esterification and a second reaction space for trans-esterification, allowing both processes to occur in one continuous operation without material transfer between separate facilities, thereby eliminating transfer time while maintaining independent reaction optimization through separate reaction zones.
Solution Approach 2:
The integrated reactor is segmented into distinct reaction spaces - a first reaction space for direct esterification and a second reaction space for trans-esterification. This segmentation allows each reaction process to be optimized independently with appropriate catalysts, temperatures, and residence times while occurring simultaneously in one integrated system, resolving the contradiction between independent optimization and transfer time reduction.
2Ease of operation
If multiple separate equipment units are used for reaction and separation processes, then each process can be independently controlled, but facility space and equipment complexity increase
Solution Approach 1:
The patent integrates multiple process functions into a single reaction system. The integrated reactor combines both esterification reaction spaces, and the alcohol recovery system combines separation, purification, and recirculation functions into one coordinated system. This merging reduces the number of separate equipment units while maintaining independent process control through dedicated control mechanisms for each reaction space and the recovery system.
Solution Approach 2:
The integrated reactor serves multiple functions - it performs both direct esterification and trans-esterification reactions within its structure. The alcohol recovery system performs multiple functions including separation of reaction products, purification of recycled alcohol, and recirculation back to the reaction spaces. This multi-functionality reduces overall equipment complexity while maintaining independent control capabilities.
3Ease of manufacture
If traditional separate process systems are used, then process steps can be clearly defined, but production efficiency decreases due to redundant equipment and transfer processes
Solution Approach 1:
The patent merges the direct esterification and trans-esterification processes into one integrated reaction system with clearly defined first and second reaction spaces. The alcohol recovery system is integrated to directly recirculate purified alcohol back to the reaction spaces. This eliminates redundant equipment and intermediate transfer processes, significantly improving production efficiency while maintaining clear process definition through the segmented reaction spaces and structured recovery system.
4Strength
If phthalate-based plasticizers are used to achieve flexibility and durability, then PVC product performance is improved, but environmental harm and health risks increase due to leakage
Solution Approach 1:
The patent changes the chemical composition parameters of the plasticizer by producing terephthalate-based plasticizers instead of phthalate-based ones. The process uses terephthalic acid or its derivatives as raw materials to synthesize terephthalate esters, which have similar flexibility and durability properties but lack the environmental harm and health risks associated with phthalates. This parameter change in chemical structure eliminates the harmful effects while preserving the desired mechanical properties.
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 facility space, eliminates redundant equipment, and shortens process time, resulting in an efficient, economical, and simplified ester composition preparation system that enhances productivity and economic efficiency by reusing mixed alcohols.
Implementation Method 1
a gas-liquid separation column having a gas-liquid separation space, into which a gasified reaction product and a gas phase low boiling point mixture from the integrated reactor flow
Implementation Method 2
a purification unit having a purification bath, in which an ester composition flowed out through the lower outlet line of the integrated reactor and the second alcohol are separated
Implementation Method 3
a mixed alcohol separation column having an alcohol separation space, into which the mixed alcohol flows from the alcohol tank and in which the mixed alcohol is separated depending on the number of alkyl carbon atoms of the alcohol
Data Source
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AI summary
The present invention provides an ester composition preparation system, including an integrated reactor, a gas-liquid separation column, a purification unit, an alcohol storage tank, and a mixed alcohol separation column, which is an efficient, economical, and simplified ester composition preparation system. According to the present invention, an ester composition preparation system, which is a simplified system which can reduce facility space, drastically remove reaction equipment, and reduce transfer time through the introduction of the integrated reactor in which the reaction preparing an ester compound and the reaction preparing an ester composition are carried in one space, the mixed alcohol separation column and the gas-liquid separation column, and an ester composition preparation method using the same, can be provided.