High-Pressure Isosorbide Dehydration Using Organic Sulfonic Acid Catalysts
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Current methods for producing isosorbide under high-pressure conditions using sulfuric acid catalysts result in low yields and high operating costs due to side reactions and equipment corrosion, while vacuum reactions offer higher yields but are energy-intensive and costly.
Innovation Solution
A method involving dehydration of sugar alcohol at high pressure (10-50 bar) using a catalyst with a boiling point of 160°C or higher, acidity between -3.0 and 3.0, and reacting in a homogeneous phase to suppress side reactions and increase isosorbide yield.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Temperature
If sulfuric acid catalyst is used in high-pressure reaction, then reaction can proceed at high temperature, but side reactions increase and yield decreases
Solution Approach 1:
The patent changes the chemical parameter of the catalyst from sulfuric acid (strong acid) to organic sulfonic acid catalysts with controlled acidity (pKa between 0 and 3). This parameter change allows the reaction to proceed at high temperatures (150-350°C) while suppressing side reactions that occur with stronger acids, thereby maintaining high isosorbide yield.
Solution Approach 2:
The patent uses organic sulfonic acid catalysts that are less acidic and can be used in high-pressure reactions without causing severe corrosion. These catalysts enable high-temperature operation with acceptable stability, allowing the process to achieve high yields without requiring expensive corrosion-resistant equipment for extended periods.
2Productivity
If sulfuric acid catalyst is used, then dehydration reaction is effective, but equipment corrosion increases
Solution Approach 1:
The patent changes the acidity parameter of the catalyst from sulfuric acid (pKa ≈ -3) to organic sulfonic acids with pKa between 0 and 3. This reduction in acidity maintains sufficient catalytic activity for dehydration while significantly reducing the corrosiveness to reaction equipment, eliminating the need for expensive corrosion-resistant reactors.
3Productivity
If vacuum reaction is used, then isosorbide yield is high, but energy consumption increases
Solution Approach 1:
Instead of using vacuum conditions to remove water and drive the dehydration reaction forward, the patent inverts the approach by using high pressure (1-20 MPa) combined with a carefully selected organic sulfonic acid catalyst. This catalyst enables the reaction to proceed efficiently under high pressure without requiring vacuum conditions, thereby eliminating the high energy consumption associated with maintaining vacuum while still achieving high isosorbide yields.
4Speed
If high-pressure reaction with sulfuric acid is used, then reaction rate increases, but operating cost increases
Solution Approach 1:
The patent changes the catalyst from sulfuric acid to organic sulfonic acids with controlled pKa values (0-3). These catalysts maintain high reaction rates under high-pressure conditions while being less corrosive and requiring less expensive equipment. The reduced equipment cost and lower energy requirements for pressure maintenance result in lower operating costs despite maintaining high reaction rates.
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 method achieves isosorbide yields comparable to vacuum reactions while reducing energy consumption and equipment costs by using a less acidic catalyst that maintains activity and prevents by-product formation, thereby enhancing process efficiency and cost-effectiveness.
Implementation Method 1
dehydrating sugar alcohol at high pressure (10-50 bar) in the presence of a catalyst
Implementation Method 2
dehydration of sugar alcohol at high pressure (10-50 bar) using a catalyst with a boiling point of 160°C or higher, acidity between -3.0 and 3.0
Data Source
AI summary
The present invention relates to a method of producing anhydrosugar alcohol by dehydrating sugar alcohol at high pressure in the presence of a catalyst which is less acidic than a conventional sulfuric acid catalyst and which can suppress side reactions at high temperature. According to the present invention, anhydrosugar alcohol can be produced in a yield similar to that in a vacuum reaction.