FDCA Purification via Solvent Displacement and Post Oxidation
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Solution Overview
Problem
Current processes for producing furan-2,5-dicarboxylic acid (FDCA) face challenges in achieving high yields while minimizing solvent and starting material loss, and existing purification methods generate wasteful by-products.
Innovation Solution
A process involving the oxidation of 5-(hydroxymethyl)furfural (5-HMF) or its derivatives in the presence of an oxidizing gas stream, a solvent stream, and a catalyst system comprising cobalt, manganese, and bromine, with temperature control between 100°C to 220°C, to produce FDCA, followed by impurity removal and crystallization to achieve high purity and yield.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If existing purification methods are used for crude FDCA, then purification is achieved, but wasteful by-products are generated
Solution Approach 1:
The patent extracts and removes impurities from the crude FDCA oxidation mixture through filtration and liquid-liquid extraction methods. The crude reaction mixture is filtered to remove solid impurities, and then extracted with organic solvents to separate and remove remaining impurities, achieving purification while minimizing waste generation compared to conventional methods
Solution Approach 2:
The patent recovers and recycles the organic solvent used in the extraction process. The solvent containing dissolved impurities is separated from the purified FDCA, and the solvent is then recovered and reused in subsequent extractions, reducing waste and improving process efficiency
2Productivity
If oxidation conditions are optimized for high FDCA yield, then production efficiency improves, but solvent and starting material loss increases
Solution Approach 1:
The patent optimizes oxidation reaction parameters including temperature (60-100°C), pH (2-4), and oxidation time to achieve high FDCA yield while minimizing degradation and loss of starting material. These controlled parameter changes maximize product formation under mild conditions that prevent excessive solvent evaporation and material decomposition
Solution Approach 2:
The patent employs continuous oxidation monitoring and controlled addition of oxidizing agent to maintain optimal reaction conditions throughout the process. This continuous control ensures complete conversion of starting material to FDCA without excessive oxidation that would cause material loss, while the reaction conditions are maintained to minimize solvent loss
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 minimal solvent and starting material loss, reducing waste generation and improving the efficiency of the FDCA production process.
Implementation Method 1
oxidizing at least one oxidizable compound selected from the following group: 5-(hydroxymethyl)furfural (5-HMF), 5-HMF esters, 5-HMF ethers, 5-alkyl furfurals in the presence of oxygen, a saturated organic acid solvent having from 2-6 carbon atoms, and a catalyst system at a temperature of about 100°C to about 220°C to produce the carboxylic acid composition comprising furan-2,5-dicarboxylic acid
Implementation Method 2
a catalyst system at a temperature of about 100°C to about 220°C to produce the carboxylic acid composition comprising furan-2,5-dicarboxylic acid
Implementation Method 3
removing impurities from a crude carboxylic acid slurry in a liquid displacement zone to form a low impurity slurry stream
Implementation Method 4
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
Implementation Method 5
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
Implementation Method 6
the resulting cooled crystallized slurry stream is routed to a solid-liquid separation zone to generate a purified wet cake stream comprising FDCA
Implementation Method 7
that is dried in a drying zone to generate a dry carboxylic acid product stream comprising purified FDCA (pFDCA)
Data Source
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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).