Furfural Derivative Recovery via Segmented Solvent Extraction
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Solution Overview
Problem
The separation of furfural derivatives and by-products from acid-catalyzed fructose and glucose conversion mixtures is challenging due to the formation of azeotropic mixtures with water and the presence of liquid hydroxyl group-containing organic compounds, which hampers efficient extraction and recycling, leading to environmental concerns and reduced production efficiency.
Innovation Solution
A process involving the reaction of fructose- and/or glucose-containing starting materials with a liquid hydroxyl group-containing organic compound, followed by neutralization to a pH range of 3 to 6.5, separation of streams, and solvent extraction using 4-methyl-2-pentanone, propyl acetate, or toluene to efficiently recover furfural derivatives and reduce by-product concentrations, thereby minimizing environmental impact and increasing production efficiency.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If liquid hydroxyl group-containing organic compounds are used in acid-catalyzed fructose/glucose conversion, then reaction efficiency is improved, but separation efficiency deteriorates due to azeotropic mixture formation and co-solvent effects
Solution Approach 1:
The process divides the separation operation into multiple stages: first separating the organic compound from the reaction mixture, then performing extraction on the remaining aqueous phase. This segmentation allows each separation step to target specific components, overcoming the limitations of attempting single-stage separation of complex azeotropic mixtures.
Solution Approach 2:
The invention uses solvent extraction with specific solvents (methyl isobutyl ketone, propyl acetate, or toluene) to selectively extract furfural derivatives from the aqueous reaction mixture. This extraction process separates the desired product from by-products and the liquid hydroxyl group-containing organic compound, resolving the separation efficiency problem.
2Reliability
If neutralization is carried out to high pH values (≥7.5), then product stability is improved, but extraction efficiency deteriorates due to compound buildup in recycle streams
Solution Approach 1:
The invention optimizes the neutralization pH to a specific range (3-6.5) rather than using high pH values. This parameter change prevents the formation of compounds that would buildup in recycle streams while still maintaining adequate product stability. The optimal pH range balances both product stability and extraction efficiency.
3Manufacturing precision
If multiple separation steps are performed to remove by-products, then product purity is improved, but processing time increases
Solution Approach 1:
The invention combines the removal of the liquid hydroxyl group-containing organic compound and the extraction of furfural derivatives into an integrated two-step process. The first separation removes the organic compound, and the subsequent extraction simultaneously purifies the furfural derivative while removing by-products. This merging of functions achieves high purity without excessive processing time.
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 reduces the concentration of furfural derivatives and by-products in waste streams, meeting stringent environmental requirements, and allows for faster separation and recovery of desired products, limiting the buildup of compounds like methoxymethylfurfural and formic acid in solvent recycle, thus enhancing extraction efficiency and product yield.
Implementation Method 1
reacting a fructose- and/or glucose-containing starting material with a liquid hydroxyl group-containing organic compound in the presence of an acid to produce an acid reaction mixture comprising the furfural derivative of chemical formula (1) and by-products
Implementation Method 2
neutralizing at least part of the acid reaction mixture obtained in step (i) to a pH-value in the range of 3 to 6.5 to provide a partially neutralized reaction mixture
Implementation Method 3
contacting at least part of the depleted stream obtained in step (iii) with a solvent selected from the group consisting of 4-methyl-2-pentanone, propyl acetate and toluene to obtain a mixture of the solvent and the depleted stream
Data Source
AI summary
A process for the preparation of a furfural derivative includes (i) reacting a fructose- and/or glucose-containing starting material with a liquid hydroxyl group-containing organic compound in the presence of an acid to produce an acid reaction mixture including the furfural derivative; (ii) neutralizing at least part of the acid reaction mixture obtained in step (i) to provide a partially neutralized reaction mixture, (iii) separating at least part of the partially neutralized reaction mixture obtained in step (ii) to obtain a stream depleted of furfural derivative and a stream including furfural derivative; (iv) contacting at least part of the depleted stream obtained in step (iii) with a solvent to obtain a mixture of the solvent and the depleted stream; and (v) separating at least part of the mixture obtained in step (iv) into solvent containing the furfural derivative and a stream further depleted of the furfural derivative.