Halogenated Alkane Process Absorption and Recycling
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Solution Overview
Problem
Current processes for preparing halogenated alkanes, such as chlorinated propanes, face issues with reproducibility, variable yields, high waste generation, and high manufacturing costs due to inefficient absorption and recycling of reactants in telomerization reactions.
Innovation Solution
A process involving a reaction mixture of halogenated methane, an alkene, and a catalyst, with an absorption device like a packed column to increase alkene absorption into the liquid phase, enhancing reaction kinetics and efficiency, and incorporating recycling strategies to reduce waste and costs.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If the alkene or halogenated alkene is used in excess to maintain concentration in the liquid phase, then the reaction kinetics and rates are maintained, but the unreacted alkene is purged as waste increasing loss of substance
Solution Approach 1:
The patent implements a recycling system where the headspace alkene is compressed and recirculated back to the reactor bottom, recovering the unreacted alkene instead of purging it as waste. This resolves the contradiction by maintaining sufficient alkene concentration for reaction kinetics while recovering the excess alkene to prevent substance loss.
Solution Approach 2:
The patent uses compression technology to recirculate the headspace alkene back to the reactor. By applying pneumatic compression, the alkene gas is compressed and returned to the liquid phase at the reactor bottom, enabling efficient recycling and reducing waste while maintaining reaction rates.
2Quantity of substance
If mechanical devices like gas inducing impellers are used to increase alkene absorption, then absorption is improved, but device complexity and manufacturing cost increase
Solution Approach 1:
The patent extracts the alkene from the headspace using compression and recirculates it to the reactor bottom, separating the absorption function from complex mechanical mixing devices. This resolves the contradiction by achieving effective alkene utilization without requiring complex gas-induced impellers or special mechanical absorption devices.
3Loss of substance
If alkene recycling equipment is used to reduce waste, then loss of substance is reduced, but device complexity and manufacturing cost increase
Solution Approach 1:
The patent merges the compression and recirculation functions into an integrated system where the headspace alkene is compressed and returned to the reactor bottom through a combined pathway. This resolves the contradiction by reducing alkene waste through recycling while minimizing device complexity through functional integration.
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
The process achieves higher yields, improved reproducibility, reduced waste, and lower manufacturing costs by increasing alkene concentration in the liquid phase and recycling reactants, leading to more efficient production of halogenated alkanes like 1,1,1,3-tetrachloropropane and 1,1,1,3,3-pentachloropropane.
Implementation Method 1
an absorption device comprising a packed column, a tray column, or combinations thereof... the absorption device provides an increased concentration of the alkene, halogenated alkene, or combinations thereof in the liquid phase
Data Source
AI summary
The present invention provides improved processes for preparing halogenated alkanes. The processes comprise reacting an alkene, a halogenated alkene, or combinations thereof and a halogenated methane with at least one chlorine atom, while using an absorption device.