Integrated Co-Production of Fluorinated Propenes
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Solution Overview
Problem
The existing methods for producing chlorofluorocarbons and hydrofluorocarbons as foam-blowing agents face challenges due to environmental concerns, such as ozone layer damage and high Global Warming Potential, and lack an efficient integrated process for co-producing HCFO-1233zd (E), HFC-245fa, and HFO-1234ze (E) without forming azeotropic compositions that complicate separation.
Innovation Solution
An integrated manufacturing process that co-produces HCFO-1233zd (E), HFC-245fa, and HFO-1234ze (E) using a single unsaturated hydrochlorocarbon feed material, involving a three-reactor system with liquid or vapor phase reactions and purification operations, which avoids intimate contact between certain compounds to facilitate separation and allows for flexible production adjustments and raw material recycling.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If conventional separation techniques such as distillation are used to separate HCFO-1233zd (E) and HFC-245fa, then separation is required to obtain pure products, but the compounds form an azeotropic composition that makes separation impossible
Solution Approach 1:
The patent extracts HCFO-1233zd (E) from the reaction mixture in the first reactor before it can form an azeotropic composition with HFC-245fa. By removing the compound that would cause separation difficulties, the remaining HFC-245fa can be obtained without complex azeotropic separation processes
Solution Approach 2:
The patent segments the production process into three separate reactor lines, where each reactor produces one specific product. This segmentation prevents the formation of mixed product streams that would require complex separation, allowing each product to be manufactured independently and then combined according to market demand
2Productivity
If separate production processes are used for HCFO-1233zd (E), HFC-245fa, and HFO-1234ze (E), then each product can be manufactured independently, but the process lacks efficiency and synergies
Solution Approach 1:
The patent creates a universal production system where a single feed material (unsaturated hydrochlorocarbon) can be converted into three different products through three reactor lines. The system can operate in multiple modes: producing all three products simultaneously, producing two products, or producing one product, providing both efficiency through integration and flexibility through adjustable operation
3Productivity
If integrated co-production is implemented, then production efficiency and synergies are achieved, but the process complexity increases
Solution Approach 1:
The patent manages process complexity by segmenting the integrated production into three distinct reactor lines, each dedicated to producing one specific product. This modular segmentation allows the complex integrated process to be operated and controlled as simpler independent units, reducing operational complexity while maintaining production 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
This process achieves high selectivity and yield for HCFO-1233zd (E) and HFO-1234ze (E), avoids product losses due to azeotropic separation issues, and allows for flexible production of each compound based on market demand, while maximizing raw material utilization and recovering by-products for commercial value.
Implementation Method 1
a combined liquid or vapor phase reaction/purification operation which directly produces HCFO-1233zd (E)
Implementation Method 2
HCFO-1233zd (E) is reacted with HF in the presence of catalyst to produce HFC-245fa
Implementation Method 3
a third reactor is used for dehydrofluorination to produce HFO-1234ze (E) by contacting in the liquid phase with a caustic solution or in the vapor phase using a dehydrofluorination catalyst
Implementation Method 4
This operation may be followed by one or more purification processes to recover the HFO-1234ze (E) product
Data Source
AI summary
Disclosed is an integrated manufacturing process to co-produce (E) 1-chloro-3,3,3-trifluoropropene, (E) 1,3,3,3-tetrafluoropropene, and 1,1,1,3,3-pentafluoro-propane starting from a single starting feed material or a mixture of unsaturated hydrochlorocarbon feed materials comprising 1,1,1,3-tetrachloropropene and/or 1,1,3,3-tetrachloropropene. The process includes a combined liquid or vapor phase reaction/purification operation which directly produces (E) 1-chloro-3,3,3-trifluoro-propene (1233zd (E)) from these feed materials, which may also include 240fa. In the second liquid phase fluorination reactor 1233zd (E) is contacted with HF in the presence of catalyst to produce 1,1,1,3,3-pentafluoropropane (245fa) with high conversion and selectivity. A third reactor is used for dehydrofluorination of 245fa to produce (E) 1,3,3,3-tetrafluoropropene (1234ze (E)) by contacting in the liquid phase with a caustic solution or in the vapor phase using a dehydrofluorination catalyst. This operation may be followed by one or more purification processes to recover the 1234ze (E) product.