Ester Production Reactor Feedback Control for Stable Operation
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Solution Overview
Problem
Existing methods for producing carbonate esters and oxalic esters face challenges in maintaining stable and efficient production, as the concentration of nitrite ester affects reaction rates and safety, requiring precise control to prevent excessive variation and ensure continuous operation without shutdowns.
Innovation Solution
A method involving a reactor system where carbon monoxide, nitrite ester, and nitric oxide are introduced with a catalyst to produce esters, followed by absorption, distillation, and recycling, with real-time measurement and adjustment of nitrite ester and nitric oxide concentrations to maintain optimal levels, using non-dispersive infrared analysis for precise monitoring.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If the concentration of nitrite ester in raw materials is increased to maintain reaction rate, then productivity is improved, but safety is deteriorated
Solution Approach 1:
The patent implements a feedback control system where the concentration of nitrite ester in the raw material gas is continuously measured, and based on this measurement, the flow rates of carbon monoxide and nitrite ester are automatically adjusted to maintain the concentration within a predetermined range. This closed-loop control prevents the concentration from becoming excessively high (which would compromise safety) while ensuring it remains sufficient to maintain an appropriate reaction rate.
Solution Approach 2:
The patent dynamically adjusts the flow rate parameters of carbon monoxide and nitrite ester based on real-time concentration measurements. By changing these parameters adaptively rather than using fixed values, the system can maintain optimal reaction conditions while preventing safety issues associated with excessively high nitrite ester concentrations.
2Productivity
If the concentration of nitrite ester is kept high to maintain reaction rate, then productivity is improved, but the variation of composition becomes excessive leading to unstable operation
Solution Approach 1:
The feedback control system continuously monitors nitrite ester concentration and makes real-time adjustments to flow rates, preventing excessive composition variations. This ensures stable operation by keeping the concentration within a controlled range rather than allowing it to fluctuate widely.
Solution Approach 2:
By dynamically adjusting flow rate parameters based on real-time measurements, the system maintains consistent composition within the reaction mixture, preventing the excessive variation that would lead to unstable operation while still maintaining sufficient concentration for adequate reaction rate.
3Device complexity
If continuous production is interrupted for maintenance or operation changes, then device complexity for stable operation is reduced, but loss of time and productivity increases
Solution Approach 1:
The feedback control system enables stable continuous operation by automatically maintaining nitrite ester concentration within optimal ranges, preventing catalyst deactivation and other issues that would require shutdowns. This automation allows the system to run continuously without frequent interruptions for maintenance or adjustments.
Solution Approach 2:
The patent implements a continuous production process where the feedback control system ensures stable operation over extended periods. The automatic adjustment of flow rates maintains optimal reaction conditions continuously, eliminating the need for periodic shutdowns and enabling uninterrupted production.
4Ease of operation
If the concentration of nitrite ester is allowed to vary freely, then ease of operation is improved, but manufacturing precision of product composition deteriorates
Solution Approach 1:
The feedback control system automatically adjusts flow rates based on real-time concentration measurements, maintaining consistent product composition without requiring manual intervention. This automation achieves both ease of operation (the system self-regulates) and manufacturing precision (consistent composition is maintained).
Solution Approach 2:
The system dynamically adjusts flow rate parameters to maintain optimal nitrite ester concentration, ensuring consistent product composition. The automatic parameter adjustment eliminates the need for manual control while maintaining precise composition control.
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 stabilizes the production of carbonate and oxalic esters by maintaining optimal nitrite ester concentrations, preventing reaction rate decline and ensuring safety, allowing for continuous and efficient production.
Implementation Method 1
reacting the first gas in the presence of a catalyst to obtain a second gas containing an ester including at least one of a carbonate ester and an oxalic ester
Implementation Method 2
allowing the second gas to contact with an absorbing solution to obtain a condensate containing the ester and a noncondensable gas containing nitric oxide
Implementation Method 3
distilling the condensate to obtain the ester
Implementation Method 4
measuring the concentration of a nitrite ester in the first gas and/or the third gas
Data Source
AI summary
Provided is a production device including: a first reactor to form a second gas containing an ester and nitric oxide from a first gas containing carbon monoxide, a nitrite, and nitric oxide; an absorption column to separate the second gas and an absorbing solution into a condensate containing the ester and a noncondensable gas; a second reactor to introduce an alcohol, the noncondensable gas, and oxygen gas thereinto to form a third gas containing nitric oxide and a nitrite; a third reactor to form a fourth gas containing a nitrite from the noncondensable gas and a bottom liquid from the second reactor and to feed the fourth gas to the second reactor; a first measurement unit to measure the concentration of a nitrite in the first gas; and a first flow rate-adjusting unit to adjust the amount of the noncondensable gas to the third reactor based on the concentration.