FDCA Oxidation Process Stability via Metal Control
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Existing oxidation processes for producing 2,5-furandicarboxylic acid from 5-alkoxymethylfurfural face challenges in maintaining process stability over long periods, controlling metal incorporation into the product cake, and achieving consistent product quality, especially at industrial scales.
Innovation Solution
A process that involves oxidizing 5-alkoxymethylfurfural in the presence of a catalyst system comprising cobalt, manganese, and bromine, using a saturated organic acid solvent, and controlling the amount of controlling acids, such as hydrobromic acid or mono- or dicarboxylic acids, to manage metal incorporation and maintain process stability.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If oxidation processes use 5-alkoxymethylfurfural as starting material, then productivity and yield of FDCA are improved, but metal incorporation into the product cake increases and process stability deteriorates
Solution Approach 1:
The patent applies parameter changes by optimizing the catalyst system composition (specific ratios of cobalt, manganese, and bromine), controlling reaction temperature (160-210°C), and adjusting the amount of controlling acids to maintain process stability while achieving high FDCA yield from 5-alkoxymethylfurfural oxidation
Solution Approach 2:
The patent implements feedback control by monitoring metal incorporation into the product cake and adjusting process parameters (catalyst composition, temperature, controlling acid amounts) to maintain acceptable product quality and process stability over prolonged operation periods
2Productivity
If oxidation processes are operated over long periods, then productivity is improved, but process stability deteriorates due to difficulty in maintaining consistent product quality
Solution Approach 1:
The patent maintains manufacturing precision over long periods by optimizing reaction parameters including temperature control (160-210°C), catalyst system composition (cobalt, manganese, bromine ratios), and controlling acid amounts, allowing prolonged operation with consistent FDCA product quality
Solution Approach 2:
The patent enables continuous operation over extended periods by maintaining stable reaction conditions and preventing process degradation, ensuring consistent FDCA production quality throughout prolonged operation without significant deviation from acceptable specifications
3Productivity
If catalyst system comprises cobalt, manganese and bromine, then oxidation efficiency is improved, but metal incorporation into product cake increases
Solution Approach 1:
The patent reduces metal incorporation while maintaining oxidation efficiency by optimizing catalyst system composition (specific ratios of cobalt, manganese, and bromine), controlling reaction temperature, and adjusting the amounts of controlling acids added during the oxidation process
Solution Approach 2:
The patent implements feedback control by monitoring metal incorporation into the product cake and adjusting catalyst composition and controlling acid amounts to maintain acceptable product quality while preserving high oxidation efficiency
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 reliable initiation and prolonged operation without deviating from acceptable product quality, effectively reduces metal incorporation into the product cake, and allows for minor adjustments to maintain process control, thereby enhancing the robustness and efficiency of the oxidation process.
Implementation Method 1
uses a catalyst system comprising cobalt, manganese and bromine to oxidize compounds having a furan moiety to FDCA using oxygen or air as an oxidizing agent
Data Source
AI summary
A process for producing a carboxylic acid composition including 2,5-furandicarboxylic acid, including the steps: a) oxidizing an oxidizable compound including 5-alkoxymethylfurfural in an oxidation reactor in the presence of a saturated organic acid solvent having from 2 to 6 carbon atoms and a catalyst system comprising cobalt, manganese and bromine using an oxidizing gas at a temperature in the range of 160 to 210° C. to obtain a crude carboxylic acid composition including mono alkyl ester of 2,5-furandicarboxylic acid and solid 2,5-furandicarboxylic acid, b) isolating at least a portion of the solid 2,5-furandicarboxylic acid from the crude carboxylic acid composition in a solid-liquid separation zone to generate a solid cake and a mother liquor, c) determining the amount of manganese and/or cobalt in the cake, and d) increasing the amount of one or more controlling acids in the oxidation reactor.