HFO-1234ze, HFO-1225zc and HFO-1234yf compositions and processes for producing and using the compositions
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Solution Overview
Problem
Current methods for producing HFO-1234ze and HFO-1234yf require additional purification or separation steps to remove excess Z-isomer, increasing costs and complexity, while there is a need for a process that minimizes or eliminates these steps and produces compositions with specific mole percentages of HFO-1225zc and HFO-1234yf.
Innovation Solution
A method involving contacting a mixture of 1,1,1,3,3-pentafluoropropane and Z-1,3,3-tetrafluoropropene in the gas phase with a catalyst like fluorinated Cr2O3 or Cr/Ni on alumina, in the presence of an oxygen-containing gas, to produce a mixture comprising Z-1,3,3-tetrafluoropropene, E-1,3,3-tetrafluoropropene, 1,1,3,3-pentafluoropropene, and 2,3,3-tetrafluoropropene without the need for purification or separation of excess 2,3,3-tetrafluoropropene.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If catalytic dehydrofluorination of HFC-245fa is used to produce HFO-1234ze, then HFO-1234ze can be produced, but a mixture of E-isomer and Z-isomer is formed requiring additional separation or isomerization steps
Solution Approach 1:
The patent converts the harmful Z-isomer byproduct into a beneficial component by isomerizing it to the desired E-isomer in-situ within the reaction system. The Z-isomer, which would normally require costly separation and disposal, is transformed into the valuable E-isomer product, eliminating the need for separate purification steps and reducing overall process complexity.
Solution Approach 2:
The patent merges the dehydrofluorination reaction and Z-isomer isomerization into a single integrated catalytic system. By combining these two functions in one reactor with a dual-function catalyst, the process eliminates the need for separate isomerization equipment and operational steps, thereby reducing device complexity while maintaining high productivity.
2Manufacturing precision
If Z-isomer is separated and isomerized in a separate step, then E-isomer purity is improved, but additional cost and process steps are required
Solution Approach 1:
The patent transforms the Z-isomer impurity into a valuable E-isomer product through in-situ isomerization, converting a manufacturing burden into a benefit. This approach maintains high E-isomer purity while eliminating the need for costly separate isomerization operations, thereby improving ease of manufacture without sacrificing product quality.
Solution Approach 2:
The catalytic system performs self-service by automatically isomerizing the Z-isomer to E-isomer within the reaction mixture itself. The catalyst continuously converts any Z-isomer formed during dehydrofluorination into the desired E-isomer, maintaining product purity without requiring external intervention or additional processing steps.
3Ease of manufacture
If HFO-1234yf is produced as a byproduct, then the reaction pathway is simplified, but purification steps are needed to remove excess HFO-1234yf
Solution Approach 1:
The patent converts the HFO-1234yf byproduct, which would normally require purification removal, into a beneficial component by isomerizing it to HFO-1234ze in-situ. This transformation eliminates the need for purification steps to remove HFO-1234yf while maintaining reaction pathway simplicity, as the same catalyst handles both dehydrofluorination and isomerization functions.
Solution Approach 2:
The patent changes the chemical parameter of HFO-1234yf by isomerizing its double bond configuration from the 2,3-position to the 3,4-position, transforming it into HFO-1234ze. This parameter change converts a unwanted byproduct into a desired product, simplifying the overall purification requirements while maintaining the simplicity of the reaction pathway.
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 effectively produces compositions with desired mole percentages of HFO-1234ze, HFO-1225zc, and HFO-1234yf, reducing the need for additional purification steps and enhancing the economic viability of the production process.
Implementation Method 1
contacting a mixture of 1,1,1,3,3-pentafluoropropane and Z-1,3,3-tetrafluoropropene in the gas phase with a catalyst like fluorinated Cr2O3 or Cr/Ni on alumina
Data Source
AI summary
A fluoropropene composition comprising Z-1,3,3,3-tetrafluoropropene, E-1,3,3,3-tetrafluoropropene, 1,1,3,3,3-pentafluoropropene, 2,3,3,3-tetrafluoropropene, and optionally 1,1,1,3,3-pentafluoropropane wherein the 2,3,3,3-tetrafluoropropene being present in an amount of 0.00001 to 1.0%. A method of producing the fluoropropene, methods for using the fluoropropene and the composition formed are also disclosed.