Halogenated Alkane Synthesis via Jet Mixing and Ion Exchange
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Solution Overview
Problem
Current processes for preparing halogenated alkanes, such as 1,1,1,3-tetrachloropropane and 1,1,1,3,3-pentachloropropane, suffer from inefficiencies, lack of reproducibility, and inconsistent yields, particularly due to the use of batch modes and mechanical stirring with non-powdered iron catalysts.
Innovation Solution
A continuous process involving a reaction mixture of halogenated methane, an alkene or halogenated alkene, and a phosphorus-containing compound, with a metal catalyst, where jet mixing and heating are used to produce halogenated alkanes, and the process includes separation steps utilizing ion exchange resins to recycle catalysts and improve kinetics and efficiency.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of operation
If batch mode with mechanical stirring and non-powder iron catalyst is used, then the process is easier to operate, but the productivity and yield consistency are poor
Solution Approach 1:
The patent replaces mechanical stirring with jet mixing technology, where high-velocity liquid jets create intense turbulence and mixing without mechanical moving parts. This substitution resolves the contradiction by maintaining ease of operation (no mechanical stirrers to maintain) while dramatically improving productivity through enhanced mass transfer and reaction rates.
Solution Approach 2:
The patent changes the physical state of the iron catalyst from non-powder to powdered form, and changes the reaction mode from batch to continuous. These parameter changes enable consistent yield improvement while maintaining operational simplicity through continuous flow processing.
2Device complexity
If batch mode with non-powder iron catalyst is used, then the device complexity is lower, but the manufacturing precision and yield consistency are poor
Solution Approach 1:
The patent replaces mechanical stirring systems with jet mixing, eliminating complex mechanical components while improving yield consistency through superior mixing performance and enhanced mass transfer between gas and liquid phases.
Solution Approach 2:
The patent transitions from batch to continuous processing mode, ensuring continuous reaction and separation operations. This continuity eliminates the variability inherent in batch processes, dramatically improving yield consistency and manufacturing precision without increasing device complexity.
3Device complexity
If conventional separation and recycling strategies are used, then the process is simpler, but the throughput and cost efficiency are lower
Solution Approach 1:
The patent implements continuous separation and recycling operations, where product separation and catalyst recovery occur continuously rather than in discrete batch steps. This continuity enables higher throughput while maintaining process simplicity through integrated flow operations.
Solution Approach 2:
The patent introduces a phosphorus-containing compound as an intermediary that forms extractable complexes with the iron catalyst. This intermediary enables efficient continuous separation and recycling of the catalyst, improving throughput and cost efficiency without complicating the overall process.
4Ease of manufacture
If mechanical stirring with non-powder iron is used, then the equipment requirements are lower, but the reaction efficiency and throughput are moderate
Solution Approach 1:
The patent replaces mechanical stirring equipment with jet mixing technology, where liquid circulation and high-velocity jets provide mixing without mechanical stirrers. This substitution maintains low equipment requirements while dramatically improving reaction efficiency and throughput through enhanced mass transfer.
Solution Approach 2:
The patent changes the iron catalyst form to powder and implements continuous processing, which enhances reaction efficiency and throughput. These parameter changes achieve higher productivity without requiring more complex or expensive equipment.
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, purity, selectivity, and throughput compared to conventional methods, with improved recycling strategies that enhance cost efficiency and reduce impurities.
Implementation Method 1
stirring the reaction mixture comprises jet mixing
Implementation Method 2
contacting at least a portion of product stream (b) with an ion exchange resin to form product stream (c) wherein product stream (c) contains less of at least one metal ion when compared to product stream (b)
Implementation Method 3
heating the reaction mixture
Implementation Method 4
one or more of the separators is a multistage distillation column
Data Source
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AI summary
The present invention provides improved processes for preparing halogenated alkanes. In particular, the processes comprise reacting an alkene, a halogenated alkene, or combinations thereof and a halogenated methane with at least one chlorine atom.