Isomerization of 1234zc By-products in Fluoropropene Synthesis
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Solution Overview
Problem
The production of hydrofluorocarbon compounds, specifically trans-1,3,3,3-tetrafluoropropene (trans-1234ze), faces challenges with the accumulation of 1,1,3,3-tetrafluoropropene (1234zc) by-products, which are difficult to remove using traditional distillation methods due to their unknown toxicity and accumulation in reaction heavies, leading to yield losses.
Innovation Solution
A method involving the isomerization of 1234zc using catalysts such as metal halides, halogenated metal oxides, and zero-valent metals or metal alloys at suitable reaction temperatures to convert 1234zc into useful products like 1234ze and 245fa, either in the absence or presence of hydrogen fluoride, allowing for efficient removal and recycling within the manufacturing process.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If traditional distillation methods are used to remove 1234zc by-products, then the separation process is simple and equipment is minimal, but the removal efficiency is low and product yield loss increases
Solution Approach 1:
The patent changes the chemical parameters of the 1234zc by-product by introducing it to reaction conditions with HF and catalysts, transforming it from a difficult-to-separate compound into reactants (245fa and 1234ze) that can be easily separated by distillation. This parameter change from static by-product to dynamic reactant resolves the contradiction between removal efficiency and yield loss.
Solution Approach 2:
The patent converts the harmful accumulation of 1234zc by-products into a beneficial process by treating them as additional feedstock. The by-products that were previously wasted or difficult to remove are now converted into valuable products (245fa and 1234ze), turning a harmful factor into a benefit and simultaneously improving removal efficiency while eliminating yield loss.
2Duration of action of stationary object
If 1234zc accumulates in reaction heavies, then the reaction process continues uninterrupted, but the by-product becomes difficult to remove and safety concerns arise
Solution Approach 1:
The patent implements a feedback mechanism where the accumulated 1234zc by-products are continuously converted back into useful materials through reaction with HF. The system monitors and manages the by-product accumulation by feeding it back into the reaction system, maintaining continuous operation while preventing harmful accumulation through controlled conversion.
Solution Approach 2:
The patent converts the harmful accumulated by-products into beneficial reactants and products. By treating 1234zc as a recyclable material rather than waste, the system maintains continuous operation without safety concerns, as the accumulated material is continuously converted into valuable 245fa and 1234ze products.
3Productivity
If isomerization catalysts are used to convert 1234zc, then conversion efficiency increases, but additional process steps and catalyst management are required
Solution Approach 1:
The patent merges the isomerization step with the existing fluorination reaction by using the same catalyst system and reaction conditions. The catalyst that facilitates fluorination also promotes isomerization of 1234zc, combining multiple functions into a single process step and avoiding additional process complexity while maintaining high conversion efficiency.
Solution Approach 2:
The patent employs catalysts that serve multiple functions: they catalyze both the fluorination reaction and the isomerization of 1234zc by-products. This multi-functionality allows the system to achieve high conversion rates without adding separate catalyst management steps, as the same catalyst system handles both transformation processes.
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 effectively manages 1234zc by-products by achieving high conversion and selectivity rates, minimizing product yield loss and ensuring safe handling by converting 1234zc into valuable compounds, thus optimizing the trans-1234ze manufacturing process.
Implementation Method 1
contacting a composition comprising 1,1,3,3-tetrafluoropropene with at least one isomerization catalyst selected from the group consisting of metal halides, halogenated metal oxides, and zero-valent metals or metal alloys, wherein said contacting occurs at a reaction temperature sufficient to isomerize at least a portion of said 1,1,3,3-tetrafluoropropene into 1,3,3,3-tetrafluoropropene
Data Source
AI summary
The present invention involves methods for isomerization of 1234zc. Also provided are methods for managing 1,1,3,3-tetrafluoropropene produced as a byproduct in a process for synthesizing trans-1,3,3,3-tetrafluoropropene from 245fa, wherein 1234zc is converted into trans/cis-1234ze with the help of a catalyst in the absence of HF and in an isomerization reactor, or is converted into 1234zc and/or 245fa with the help of a catalyst in the presence of HF in a separate reactor or preferably in the same reactor of 245fa dehydrofluorination.