Heating-Roller Distillation for Continuous Sucrose-6-Ester Production
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Solution Overview
Problem
The existing process for synthesizing sucrose-6-ester requires the use of gas or solvent vapor for water removal, which disrupts the continuity of the production process, prolongs the cycle, and increases energy consumption and production costs.
Innovation Solution
A production apparatus with a heating-roller distillation device that rolls the reaction solution into a thin liquid film, allowing for efficient moisture removal through a distillation and esterification process without the need for additional vapor, integrating distillation, cooling, and reaction steps to enable continuous production.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Loss of energy
If gas or solvent vapor is used for water removal, then water can be removed from the reaction mixture, but the production process continuity is disrupted and production cycle is prolonged
Solution Approach 1:
The patent combines the water removal step and the esterification reaction step into a single integrated reaction vessel. The distillation apparatus is integrated directly into the reaction tank, allowing water to be removed and the esterification reaction to occur simultaneously in one continuous process, eliminating the need to switch between different vessels and maintaining continuous production.
Solution Approach 2:
The patent implements continuous water removal through distillation while the esterification reaction proceeds simultaneously. The reaction mixture is continuously heated to distill off water, and the esterification reaction continues uninterrupted in the same vessel, ensuring continuous useful action without pauses or transfers between steps.
2Loss of energy
If gas or solvent vapor is used for water removal, then water can be removed from the reaction mixture, but production cost and energy consumption increase
Solution Approach 1:
The patent uses the reaction mixture itself as the medium for water removal. Instead of introducing external gas or solvent vapor, the system utilizes the existing reaction components and heating energy to distill off water directly from the mixture, making the process self-sufficient and eliminating the need for additional costly reagents.
Solution Approach 2:
By merging the water removal and esterification steps into one integrated process in a single vessel, the patent eliminates the need for separate equipment and reagents, thereby reducing overall production costs and energy consumption while maintaining manufacturing feasibility.
3Manufacturing precision
If gas or solvent vapor is used for water removal, then water can be removed from the reaction mixture, but the production process becomes discontinuous
Solution Approach 1:
The patent merges the water removal operation with the esterification reaction operation in a single integrated vessel. The distillation apparatus is built into the reaction tank, allowing both functions to occur simultaneously in one continuous process, eliminating interruptions caused by transferring material between separate vessels.
Solution Approach 2:
The system maintains continuous operation by performing water distillation and esterification reaction simultaneously in the same vessel. The reaction mixture is continuously heated to remove water while the esterification proceeds uninterrupted, ensuring continuous useful action without pauses for vessel transfers.
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 apparatus achieves continuous production of sucrose-6-ester, reducing production time and cost by eliminating the need for bulky vapor systems, thus improving efficiency and reducing energy consumption.
Implementation Method 1
a step of reaction solution separation: turning on the heating-roller distillation device, setting each heating roller to a preset temperature, and feeding a reaction solution through a feed port of the distillation separation tank, such that the reaction solution is separated into a liquid evaporation residue and a water vapor on an outer wall of each heating roller
Implementation Method 2
condensing the water vapor into liquid water at the left and right side walls of the shell
Data Source
AI summary
A production apparatus of sucrose-6-ester is disclosed and includes a distillation separation tank, a reaction tank, and a condensated water collection tank, where the distillation separation tank is arranged above the reaction tank and the condensated water collection tank, and includes a shell and a heating-roller distillation device including a plurality of heating rollers arranged from top to bottom between front and rear side walls of the shell; two ends of the U-shaped plate are respectively fixed to bottoms of the front and rear side walls; a feed pipe is provided at a top of the shell, the condensated water outlet pipe is arranged at a bottom surface of the shell and is connected to the condensated water collection tank, and the liquid evaporation residue discharge pipe penetrates through the bottom surface of the shell, is connected to the U-shaped plate, and is connected to the reaction tank.