Extraction Tower for Neo-Acid Catalyst Recovery
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Solution Overview
Problem
Current industrial processes for producing neo-acids, such as the Shell's versatic acid process and the Exxon process, face challenges in efficiently recovering and recycling acid catalysts, particularly in removing residual salts and corrosion byproducts from reactor effluents.
Innovation Solution
A process involving the use of a boron trifluoride catalyst system with water in reactors to produce neo-acids, followed by passing the reactor effluent through an extraction tower with multiple phases for separation and recovery, allowing for efficient removal of catalysts and catalyst salts, utilizing a York-Scheibel tower configuration for enhanced extraction efficiency.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If multiple washing steps and settling drums are used to recover catalyst, then catalyst recovery is achieved, but the process complexity and time consumption increase
Solution Approach 1:
The patent combines multiple washing steps and settling operations into a single extraction tower that performs both catalyst recovery and salt removal simultaneously. The extraction tower integrates the functions of multiple settling drums into one unit, reducing process complexity while maintaining catalyst recovery efficiency through counter-current extraction with water or aqueous solutions.
Solution Approach 2:
The extraction tower is divided into multiple theoretical stages or trays that segment the extraction process into discrete steps. This segmentation allows the tower to perform multiple extraction functions in sequence within a single device, enabling both catalyst recovery and salt removal without requiring multiple separate units.
2Reliability
If multiple washing steps and settling drums are used, then catalyst recovery is improved, but the processing time increases
Solution Approach 1:
The extraction tower operates continuously with counter-current flow of reactor effluent and extractant (water or aqueous solution) through multiple theoretical stages. This continuous operation eliminates the batch processing time associated with multiple settling drums, maintaining high catalyst recovery efficiency while significantly reducing overall processing time through uninterrupted extraction.
Solution Approach 2:
The patent transitions from horizontal batch settling in multiple drums to vertical continuous extraction in a single tower. This dimensional change from horizontal to vertical processing allows multiple extraction stages to be stacked vertically, enabling continuous operation and reducing the time required for catalyst recovery compared to sequential batch settling.
3Reliability
If conventional extraction methods are used, then catalyst removal is achieved, but salt and corrosion byproduct removal is insufficient
Solution Approach 1:
The extraction tower is designed to perform multiple functions simultaneously: catalyst recovery, salt removal, and corrosion byproduct elimination. By using water or aqueous solutions as extractants in a counter-current extraction process through multiple theoretical stages, the tower achieves comprehensive purification that conventional single-function extraction methods cannot accomplish.
Solution Approach 2:
The patent uses water or aqueous solutions as a simple, universal extractant that effectively replicates and enhances the catalyst separation function while simultaneously removing salts and corrosion byproducts. This extractant choice provides a comprehensive purification effect that goes beyond conventional organic solvent extraction, achieving both catalyst recovery and high product purity.
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 enables the recovery of high-purity neo-acids with reduced catalyst and salt contamination, improving catalyst recycling and product quality by achieving low ppm levels of catalyst residues, thus enhancing the efficiency and commercial viability of neo-acid production.
Implementation Method 1
contacting at least a portion of the mixture with water; separating at least a portion of the neo-acid from the reactor effluent
Implementation Method 2
the at least one extraction tower comprises two or more phases operating at least two extractions
Data Source
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AI summary
The disclosure relates to processes and systems utilizing one or more extraction towers in the recovery and recycle of acid catalysts used in the production of carboxylic acids. The carboxylic acids may be neo-acids produced through the hydrocarboxylation of olefins or olefin mixtures.