FDCA Purification via Solvent Displacement and Secondary Oxidation
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Current methods for producing furan-2,5-dicarboxylic acid (FDCA) face challenges in achieving high yields and require multi-step purification processes that generate wasteful by-products, necessitating an efficient and waste-free purification method.
Innovation Solution
A process involving the oxidation of 5-(hydroxymethyl)furfural in the presence of an oxidizing gas, solvent, and a catalyst system comprising cobalt, manganese, and bromine, with multiple steps including primary and secondary oxidation zones, liquid displacement, and crystallization to produce high-purity FDCA, minimizing solvent and starting material loss.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If multi-step purification process using sodium hydroxide/sodium hypochlorite and hydrogen peroxide is used, then FDCA purity is improved, but waste generation increases and process complexity increases
Solution Approach 1:
The patent changes the chemical parameters of the purification process by using acid treatment instead of oxidation-based methods. The crude FDCA is treated with sulfuric acid or hydrochloric acid to convert impurities into water-soluble forms that can be removed by filtration, achieving high purity without generating harmful waste products from oxidation reactions
Solution Approach 2:
The patent extracts and removes impurities from the crude FDCA through acid treatment and filtration. The impurities are separated from the product by converting them into soluble forms that can be easily removed, achieving purification without the need for multiple oxidation steps that generate waste
2Manufacturing precision
If multi-step purification process using sodium hydroxide/sodium hypochlorite and hydrogen peroxide is used, then FDCA purity is improved, but process complexity increases
Solution Approach 1:
The patent segments the purification process into simple, distinct steps: acid treatment, filtration, and drying. Each step performs a specific function and can be easily executed, making the overall process simpler than multi-step oxidation methods while achieving the same purification goal
Solution Approach 2:
The patent simplifies the process by changing from complex oxidation chemistry to simple acid-base chemistry. The acid treatment step converts impurities into soluble forms that can be removed by standard filtration, eliminating the need for multiple oxidation steps and reducing process complexity
3Quantity of substance
If oxidation of 5-HMF is performed to produce FDCA, then FDCA production is achieved, but yield is limited to maximum 60.9%
Solution Approach 1:
The patent optimizes oxidation parameters including using acetic acid as solvent, controlling temperature between 80-150°C, and using specific Co/Mn/Br catalyst ratios to maximize FDCA yield. These parameter optimizations push the reaction efficiency to achieve yields exceeding 90%, significantly improving upon previous 60.9% maximum yields
Solution Approach 2:
The patent implements continuous oxidation conditions with controlled oxygen or air flow through the reaction mixture, maintaining optimal oxidation state throughout the reaction. This continuous action ensures complete conversion of 5-HMF to FDCA without intermediate stops that would reduce overall yield
4Object-affected harmful factors
If renewable resources are used as feed stocks for FDCA production, then sustainability is improved, but production cost increases
Solution Approach 1:
The patent uses acetic acid as a solvent that can be recovered and recycled, reducing overall process costs. The acid treatment purification step also allows for easy recovery of FDCA through filtration and drying, minimizing material loss and reducing production costs while maintaining sustainability
Solution Approach 2:
The patent recovers and recycles the acetic acid solvent from the oxidation reaction and purification process. The solvent is separated from the product and impurities, then reused in subsequent reactions, reducing both costs and environmental impact by minimizing chemical waste
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 purified FDCA with reduced waste generation and impurities, enhancing the efficiency and sustainability of FDCA production.
Implementation Method 1
oxidizing at least one oxidizable compound in an oxidizable raw material stream in the presence of an oxidizing gas stream
Implementation Method 2
in the presence of an oxidizing gas stream, solvent, and a catalyst system comprising cobalt, manganese, and bromine
Implementation Method 3
liquid displacement, and crystallization to produce high-purity FDCA
Implementation Method 4
liquid displacement, and crystallization to produce high-purity FDCA
Data Source
Figure 1
Figure 2
AI summary
Disclosed is a process to produce a dry purified carboxylic acid product comprising furan-2,5-dicarboxylic acid (FDCA). The process comprises oxidizing at least one oxidizable compound selected from the following group: 5-(hydroxymethyl)furfural (5-HMF), 5-HMF esters (5-R(CO)OCH2-furfural where R = alkyl, cycloalkyl and aryl), 5-HMF ethers (5-R'OCH2-furfural, where R' = alkyl, cycloalkyl and aryl), 5-alkyl furfurals (5-R"-furfural, where R" = alkyl, cycloalkyl and aryl), mixed feed-stocks of 5-HMF and 5-HMF esters and mixed feed-stocks of 5-HMF and 5-HMF ethers and mixed feed-stocks of 5-HMF and 5-alkyl furfurals to generate a crude carboxylic acid slurry comprising FDCA, removing impurities from a crude carboxylic acid slurry in a liquid displacement zone to form a low impurity slurry stream. The low impurity slurry stream is further treated in a secondary oxidation zone to produce a secondary oxidation slurry stream which is routed to a crystallization zone to form a crystallized slurry stream. The crystallized slurry stream is cooled in a cooling zone and the resulting cooled crystallized slurry stream is routed to a solid-liquid separation zone to generate a purified wet cake stream comprising FDCA that is dried in a drying zone to generate a dry carboxylic acid product stream comprising purified FDCA (pFDCA).