FDCA Oxidation With Modifying Acid for Higher Purity Solids
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Solution Overview
Problem
Existing processes for producing 2,5-furandicarboxylic acid from 5-methylfurfural suffer from low purity, coloration due to impurities, and incorporation of catalyst metals, particularly manganese and cobalt, which affect the quality and recyclability of the product.
Innovation Solution
A process involving the use of a modifying acid, such as bromoacetic acid, during the oxidation of 5-methylfurfural with a cobalt, manganese, and bromine catalyst system, followed by separation and washing steps to reduce biscarbonylfuroic acid and metal content, enhancing the purity and reducing absorbance.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If oxidation of 5-methylfurfural is performed using cobalt and manganese catalyst system, then conversion rate is improved, but product purity deteriorates due to metal incorporation and colored impurities
Solution Approach 1:
The patent removes harmful catalyst metals (cobalt and manganese) and colored impurities from the oxidation reaction mixture through filtration and washing steps, separating the desired 2,5-furandicarboxylic acid product from contaminants while maintaining high conversion rates
Solution Approach 2:
The patent introduces acetic acid as an intermediary substance that facilitates the oxidation reaction and helps in subsequent purification steps, acting as a medium that enables both high conversion and ease of purification by controlling the reaction environment
2Productivity
If standard oxidation process is used to produce 2,5-furandicarboxylic acid, then production efficiency is improved, but product coloration increases due to impurity formation
Solution Approach 1:
The patent converts the harmful effect of colored impurities into a manageable purification challenge by using specific washing steps with acetic acid and water that selectively remove colored contaminants while preserving the yellow-free 2,5-furandicarboxylic acid product
Solution Approach 2:
The patent changes the chemical parameters of the reaction system by controlling pH, temperature, and acid concentration during oxidation and purification, optimizing these parameters to minimize colored impurity formation and facilitate their removal
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 process achieves high purity 2,5-furandicarboxylic acid with reduced biscarbonylfuroic acid and metal impurities, improving the quality for polymerization and enabling efficient recycling of catalyst components.
Implementation Method 1
oxidizing feed comprising 5-methylfurfural using an oxidizing gas in an oxidation reactor
Implementation Method 2
catalyst system comprising cobalt, manganese and bromine
Implementation Method 3
separating solid 2,5-furandicarboxylic acid from the crude carboxylic acid composition
Implementation Method 4
separating solid 2,5-furandicarboxylic acid from the crude carboxylic acid composition
Implementation Method 5
washing the filtered solid with a washing solution comprising acetic acid and water
Implementation Method 6
reducing the amount of metal impurities and biscarbonylfuroic acid in the 2,5-furandicarboxylic acid
Data Source
AI summary
Process for producing 2,5-furandicarboxylic acid comprising the steps of: a) oxidizing feed comprising 5-methylfurfural using an oxidizing gas in an oxidation reactor at a temperature in the range of 150 to 210° C. to obtain a crude carboxylic acid composition comprising 2,5-furamndicarboxylic acid in the presence of acetic acid and a modifying acid selected from the group consisting of carboxylic acids having a pKa of less than 3.2, and a catalyst system comprising cobalt, manganese and bromine; and b) separating solid 2,5-furamndicarboxylic acid from the crude carboxylic acid composition to obtain crude solid 2,5-furandicarboxylic acid wherein the modifying acid is added to the oxidation reactor and is selected from the group consisting of bromoacetic acid, dibromoacetic acid, 5-bromo-2-furoic acid, fumaric acid, acetoxy-acetic acid, maleic acid and furoic acid.