Hydrogen Peroxide Production via Modular Remote Control
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Solution Overview
Problem
Current large-scale hydrogen peroxide production processes are complex, capital-intensive, and difficult to scale down, making them unsuitable for small to medium-scale production, particularly for local industrial applications, which require safer and more economical methods for producing hydrogen peroxide solutions.
Innovation Solution
A remotely controlled and automated process for producing hydrogen peroxide using the anthraquinone autoxidation process, where key steps are monitored and controlled via sensors interconnected with computers, allowing for remote operation and minimizing the need for local intervention, and featuring a compact modular reactor system without a regeneration unit for continuous operation.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If large-scale hydrogen peroxide production processes are used, then production capacity is high, but device complexity and capital costs increase
Solution Approach 1:
The patent divides the hydrogen peroxide production system into modular units that can be scaled. Each module contains essential components (reactor, separator, recycle system) and can be replicated or configured differently based on scale requirements, allowing medium-scale production without replicating full large-scale complexity
Solution Approach 2:
The patent extracts and eliminates the regeneration unit from the traditional large-scale process design. By removing this complex component and using alternative approaches (such as periodic regeneration or simplified catalyst replacement), the system achieves medium-scale production capability without the associated complexity and capital costs
2Productivity
If large-scale production processes are used, then productivity is high, but ease of manufacture and scalability to medium scale deteriorates
Solution Approach 1:
The process is segmented into discrete, independently configurable units that can be manufactured and assembled at medium scale. The modular design allows each unit to be optimized for medium-scale operations without requiring the infrastructure and complexity of large-scale facilities
Solution Approach 2:
The patent adjusts key process parameters (reactor volume, catalyst loading, flow rates, pressure) to be optimized for medium-scale production rather than simply downscaling large-scale parameters. This allows the process to operate efficiently at medium scale without replicating large-scale complexity
3Ease of operation
If remote control and automation are implemented, then ease of operation improves, but device complexity increases
Solution Approach 1:
The patent implements feedback control systems that automatically monitor and adjust process parameters (temperature, pressure, flow rates) based on sensor data. This allows remote operation with minimal human intervention while maintaining process stability without requiring overly complex control architectures
Solution Approach 2:
The system incorporates self-diagnostic and self-regulating capabilities where the process automatically detects and corrects common issues, reducing the need for complex remote monitoring and intervention systems while improving ease of operation
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 approach enables efficient, safe, and cost-effective production of hydrogen peroxide at small to medium scales, suitable for local use, with reduced capital costs and operational complexity, allowing for continuous operation with minimal local support and easy remote control.
Implementation Method 1
hydrogenation of a working solution in a hydrogenation unit (hydrogenator) in the presence of a catalyst, wherein said working solution contains at least one alkylanthraquinone dissolved in at least one organic solvent, to obtain at least one corresponding alkylanthrahydroquinone compound
Implementation Method 2
oxidation of said at least one alkylanthrahydroquinone compound to obtain hydrogen peroxide in an oxidation unit
Data Source
AI summary
A process for the manufacture of hydrogen peroxide by the AO-process comprising the two alternate (essential) steps of (a) hydrogenation of a working solution in a hydrogenation unit (hydrogenator) in the presence of a catalyst, wherein said working solution contains at least one alkylanthraquinone dissolved in at least one organic solvent, to obtain at least one corresponding alkylanthrahydroquinone compound; and (b) oxidation of said at least one alkylanthrahydroquinone compound to obtain hydrogen peroxide in an oxidation unit; and further comprising the step of (c) extracting the hydrogen peroxide formed in the oxidation step in an extraction unit, wherein the units of step (a) to (c), optionally together with further ancillary units as appropriate, constitute a hydrogen peroxide production site, and wherein one or more of said units are equipped with one or more sensors for monitoring one or more AO-process parameters at the hydrogen peroxide production site, said sensors being interconnected with one or more first computers at the hydrogen peroxide production site, said first computers being linked via a communication network to one or more second computers in a control room being remote from the hydrogen peroxide production site, and wherein said control room is remotely controlling said hydrogen peroxide production site.