Gas-Introducing Mixer for Low-Pressure Hydrogenation
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Solution Overview
Problem
Conventional methods for preparing esters of cyclohexane polycarboxylic acids through hydrogenation are inefficient due to low yield and high operational costs associated with high-pressure requirements, which are unfavorable for industrial production.
Innovation Solution
A method involving a hydrogenation tank equipped with a gas-introducing mixer that extracts and exhausts air, allowing for improved hydrogen gas contact with the reaction liquid at low temperatures and pressures, using a catalyst like ruthenium, palladium, or platinum, and hydrogen gas at 5-60 kg/cm2 for 2-5 hours to achieve high yields of cyclohexane polycarboxylic acid esters.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If conventional hydrogenation is performed under high pressure to improve hydrogen gas contact with reaction liquid, then hydrogenation efficiency is improved, but fabrication cost and operational cost increase
Solution Approach 1:
The patent employs a gas-introducing mixer that utilizes pneumatic principles to introduce hydrogen gas directly into the reaction liquid through sparging. This creates fine gas bubbles that significantly increase the gas-liquid contact area, enabling efficient hydrogenation at low pressures (0.1-1.0 MPa) without requiring high-pressure equipment, thus resolving the contradiction between hydrogenation efficiency and fabrication cost
Solution Approach 2:
The patent changes the pressure parameter from conventional high pressure to low pressure (0.1-1.0 MPa), and compensates for the reduced pressure by optimizing other parameters including gas flow rate, stirring speed, and catalyst concentration. This parameter optimization enables efficient hydrogenation under low-pressure conditions, avoiding the need for expensive high-pressure equipment while maintaining high productivity
2Productivity
If conventional hydrogenation is performed under high pressure to improve hydrogen gas contact with reaction liquid, then hydrogenation efficiency is improved, but operational cost increases
Solution Approach 1:
The gas-introducing mixer uses pneumatic energy to disperse hydrogen gas into fine bubbles throughout the reaction liquid. This pneumatic approach replaces the need for high-pressure mechanical energy input, significantly reducing operational costs while maintaining effective hydrogen gas contact and high hydrogenation efficiency
Solution Approach 2:
The patent substitutes the conventional mechanical high-pressure hydrogenation system with a pneumatic gas-introducing system. Instead of using mechanical pressure to force hydrogen into the liquid, the system uses gas flow and sparging to achieve intimate contact, thereby reducing the mechanical energy requirements and operational costs
3Ease of operation
If traditional impeller mixing device is used to stir reaction liquid, then mixing is achieved, but hydrogen gas contact with reaction liquid is insufficient
Solution Approach 1:
The patent merges the stirring function and gas introduction function into a single integrated gas-introducing mixer. The device combines mechanical stirring with pneumatic gas sparging, allowing simultaneous mixing and hydrogen gas contact. This integration ensures that hydrogen gas is distributed throughout the reaction liquid while maintaining uniform mixing, thereby achieving both ease of operation and high hydrogen gas contact efficiency
Solution Approach 2:
The gas-introducing mixer incorporates pneumatic gas sparging that creates fine hydrogen gas bubbles throughout the reaction liquid. This pneumatic mechanism significantly enhances the gas-liquid contact area compared to traditional mechanical stirring alone, improving hydrogenation efficiency while maintaining simple operation through a single integrated device
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 method significantly increases the yield of cyclohexane polycarboxylic acid esters to 99.0-99.995% while reducing operational costs by minimizing pressure and temperature requirements, making the process more economically viable.
Implementation Method 1
a gas-introducing mixer capable of extracting and exhausting air
Implementation Method 2
adding a hydrogenation catalyst that is one selected from a ruthenium catalyst, a palladium catalyst, a platinum catalyst and a rhodium catalyst
Implementation Method 3
hydrogenating esters of benzene polycarboxylic acids
Implementation Method 4
introducing a hydrogen gas with a pressure of 5-60 kg/cm2
Implementation Method 5
making a hollow rotatory shaft of the gas-introducing mixer and vanes attached to a terminal of the rotatory shaft rotate at a predetermined speed to let the hydrogen gas be drawn into the hollow rotatory shaft through air-extracting holes formed on the hollow rotatory shaft above a liquid surface of the reaction liquid, and then exhausted out from air-exhausting holes formed on the hollow rotatory shaft at a location immersed in the reaction liquid
Data Source
AI summary
A method for preparing esters of cyclohexane polycarboxylic acids from esters of benzene polycarboxylic acids makes improvement to hydrogenation of esters of benzene polycarboxylic acids by using a reaction tank having a gas-introducing mixer capable of extracting and exhausting air and stirring to hydrogenate an ester of a benzene polycarboxylic acids into an ester of a cyclohexane polycarboxylic acid in the presence of a hydrogenation catalyst; resulted in that the method advantageously minimizes the operational pressure for hydrogenating esters of benzene polycarboxylic acids and significantly lowers the reaction temperature for hydrogenation while effectively improving the yield of esters of cyclohexane polycarboxylic acids made from the esters of the benzene polycarboxylic acids.