FDCA Purge Process Solving Catalyst Recovery and Carbon Burn

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Solution Overview

Problem

Current methods for producing furan-2,5-dicarboxylic acid (FDCA) face challenges in solvent and catalyst recovery, as well as by-product and impurity removal, leading to inefficient processes and material loss during oxidation.

Innovation Solution

A process involving the oxidation of 5-(hydroxymethyl)furfural (5-HMF) and its derivatives using a cobalt, manganese, and bromine catalyst system in an acetic acid solvent, followed by cooling and solid-liquid separation to recover solvent, catalyst, and impurities, with a focus on minimizing carbon burn and optimizing yields.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Productivity

If oxidation is performed using homogenous catalysts to produce FDCA, then the reaction efficiency is improved, but solvent and catalyst recovery becomes difficult and material loss increases

Engineering Contradiction:

Improvereaction efficiencyVSAvoidsolvent and catalyst loss

Core Design Contradiction:

ProductivityVSLoss of substance

Solution Approach 1:

The patent extracts the catalyst from the homogeneous mixture by converting it to a heterogeneous form through precipitation with base metals or adsorption onto solid supports. This allows the catalyst to be separated from the reaction mixture via filtration, enabling recovery and reuse while maintaining high reaction efficiency during the oxidation process.

Inventive Principle:

Principle #2Taking out (Extraction)

Solution Approach 2:

The patent implements a catalyst recovery system where the homogeneous catalyst is converted to a recoverable form through precipitation or adsorption. The spent catalyst is then filtered out and regenerated, while the solvent is distilled and reused. This closed-loop approach minimizes material loss while maintaining productive oxidation reactions.

Inventive Principle:

Principle #34Discarding and recovering

2Quantity of substance

If oxidation reactions are conducted to convert 5-HMF to FDCA, then the production of valuable diacid is achieved, but by-products and impurities are generated that require extensive purification

Engineering Contradiction:

ImproveFDCA productionVSAvoidpurification loss

Core Design Contradiction:

Quantity of substanceVSLoss of substance

Solution Approach 1:

The patent performs preliminary purification actions by selecting oxidation conditions and catalyst systems that minimize by-product formation from the start. The process is designed to favor FDCA formation while suppressing side reactions, reducing the burden on subsequent purification steps and minimizing material loss during purification.

Inventive Principle:

Principle #10Preliminary action

Solution Approach 2:

The patent optimizes reaction parameters including temperature, oxygen pressure, catalyst composition, and solvent type to maximize FDCA selectivity. By carefully controlling these parameters, the process achieves high conversion rates with minimal by-product formation, reducing purification requirements and material loss.

Inventive Principle:

Principle #35Parameter changes

3Productivity

If high yields of FDCA are achieved through optimized oxidation, then production efficiency is improved, but solvent and starting material loss through carbon burn increases

Engineering Contradiction:

ImproveFDCA yieldVSAvoidcarbon burn loss

Core Design Contradiction:

ProductivityVSLoss of substance

Solution Approach 1:

The patent optimizes oxidation parameters including oxygen partial pressure, temperature, and catalyst composition to achieve high FDCA yields while suppressing complete combustion. The process operates in a controlled regime where partial oxidation to FDCA is favored over total oxidation to CO2, minimizing carbon burn loss while maintaining high productivity.

Inventive Principle:

Principle #35Parameter changes

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 process achieves high yields of FDCA while minimizing solvent and starting material loss through carbon burn, effectively recovering valuable components and reducing impurities, thereby enhancing the efficiency and sustainability of the production process.

Implementation Method 1

oxidizing a feed stream comprising at least one oxidizable compound selected from the following group: 5-(hydroxymethyl)furfural (5-HMF), 5-HMF esters, 5-HMF ethers, 5-alkyl furfurals to generate a crude carboxylic acid slurry comprising furan-2,5-dicarboxylic acid (FDCA)

Methodology Applied

Scientific EffectOxidation: Oxidation

Implementation Method 2

using a cobalt, manganese, and bromine catalyst system in an acetic acid solvent

Methodology Applied

Scientific EffectCatalysis: Catalysis

Implementation Method 3

cooling a crude carboxylic acid slurry in a cooling zone to generate a cooled crude carboxylic acid slurry

Methodology Applied

Scientific EffectCooling: Cooling

Implementation Method 4

removing impurities from a cooled crude carboxylic acid slurry in a solid-liquid separation zone to form a low impurity carboxylic acid stream and a mother liquor stream

Methodology Applied

Scientific EffectSolid-liquid separation: Sedimentation

Data Source

PatentUS11027263B2Furan-2,5-dicarboxylic acid purge process

Publication Date: 2021.06.08 EASTMAN CHEM CO

AI summary

Disclosed is an oxidation process to produce a crude carboxylic acid product carboxylic acid product. The process comprises oxidizing a feed stream comprising at least one oxidizable compound to generate a crude carboxylic acid slurry comprising furan-2,5-dicarboxylic acid (FDCA) and compositions thereof. Also disclosed is a process to produce a dry purified carboxylic acid product by utilizing various purification methods on the crude carboxylic acid.