FDCA Purge Process for Solvent Recovery and Impurity Removal
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Solution Overview
Problem
The production of furan-2,5-dicarboxylic acid (FDCA) from 5-(hydroxymethyl)furfural (5-HMF) faces challenges in solvent and catalyst recovery, as well as by-product and impurity removal, leading to inefficiencies and environmental impacts due to high carbon burn and solvent loss.
Innovation Solution
A process is developed to recover oxidation solvent, catalyst, and remove by-products and impurities from the solvent stream by oxidizing 5-HMF or its derivatives using a Co/Mn/Br catalyst system in an oxidation zone, followed by cooling, solid-liquid separation, and recycling of solvent and catalyst, minimizing carbon burn and solvent loss.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If oxidation of 5-HMF is performed using Co/Mn/Br catalyst system, then FDCA yield is improved, but solvent and starting material loss increases due to carbon burn
Solution Approach 1:
The patent implements a mother liquor purge zone that separates and recovers valuable components (solvent and catalyst) from the oxidation mixture. The purge stream is treated to recover solvent for recycling back to the oxidation zone, and catalyst is recovered for reuse. This prevents solvent and starting material loss while maintaining high FDCA yield through the Co/Mn/Br catalyst system.
Solution Approach 2:
The patent establishes a feedback loop where the mother liquor is analyzed and adjusted before being recycled back to the oxidation zone. The purge stream composition is monitored and used to optimize the oxidation conditions, catalyst composition, and solvent recovery parameters. This continuous feedback mechanism maintains high productivity while minimizing substance loss through optimized process control.
2Productivity
If oxidation reaction is conducted to produce FDCA, then product yield is improved, but by-product and impurity accumulation increases
Solution Approach 1:
The patent employs a solid-liquid separation zone that extracts and removes impurities from the oxidation mixture. The separation process divides the mixture into a solid stream (containing FDCA and impurities) and a liquid stream (mother liquor). The solid stream is further processed to remove impurities, and the purified FDCA is recovered. This extraction approach maintains high productivity while effectively removing harmful by-products and impurities.
Solution Approach 2:
The patent segments the oxidation process into distinct zones: oxidation zone, cooling zone, solid-liquid separation zone, and mother liquor purge zone. Each zone performs a specific function to manage by-products and impurities at different stages. The oxidation zone produces FDCA, the separation zone removes impurities, and the purge zone recovers valuable components. This segmentation allows high productivity while systematically managing harmful factors at each process stage.
3Productivity
If solvent and catalyst are recycled, then process efficiency is improved, but contamination with impurities increases
Solution Approach 1:
The patent implements preliminary purification actions before recycling solvent and catalyst. The mother liquor undergoes treatment in the solid-liquid separation zone to remove impurities before being recycled to the oxidation zone. The purge stream is processed to recover pure solvent and catalyst components. This preliminary purification ensures that recycled materials maintain high reliability and purity, preventing contamination accumulation while preserving process efficiency.
Solution Approach 2:
The patent utilizes parameter changes in the mother liquor purge zone to optimize the separation and purification of recycled streams. Temperature, pressure, and flow rate parameters are adjusted to maximize the purity of recovered solvent and catalyst. By controlling these parameters, the system achieves high-purity recycled streams that maintain reliability for subsequent oxidation cycles while preserving process efficiency through effective recycling.
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 reducing solvent and starting material loss, and effectively recycles oxidation solvent and catalyst, enhancing process efficiency and environmental sustainability.
Implementation Method 1
oxidizing 5-HMF or its derivatives using a Co/Mn/Br catalyst system in an oxidation zone
Implementation Method 2
oxidizing 5-HMF or its derivatives using a Co/Mn/Br catalyst system
Implementation Method 3
cooling a crude carboxylic acid slurry in a cooling zone to generate a cooled crude carboxylic acid slurry
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
Data Source
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.