Laurolactam Synthesis via Solid Acid Catalysts
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Solution Overview
Problem
Current laurolactam preparation methods face challenges such as the generation of large amounts of by-products requiring extensive facilities for treatment, complex processes, and low yield due to the use of strong acids like sulfuric acid as catalysts, which complicates the recovery and recycling of catalysts and solvents.
Innovation Solution
A method involving the synthesis of epoxidized cyclododecane, cyclododecanone, and cyclododecanone oxime using specific catalysts and reactors, followed by a Beckmann rearrangement reaction to produce laurolactam, simplifying the process and improving yield and purity.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If concentrated sulfuric acid or fuming sulfuric acid is used as catalyst in Beckman rearrangement reaction, then the reaction can proceed, but a large amount of ammonium sulfate by-product is generated requiring extensive treatment facilities
Solution Approach 1:
The patent changes the chemical parameter of the catalyst from concentrated sulfuric acid to a solid acid catalyst (ammonium tungstate or ammonium molybdate), which fundamentally alters the reaction system to eliminate ammonium sulfate by-product formation while maintaining high conversion rates and selectivity for laurolactam production
Solution Approach 2:
The patent employs a solid acid catalyst that can be easily separated and potentially reused, replacing the conventional sulfuric acid system that generates problematic by-products requiring extensive treatment facilities
2Productivity
If conventional Beckman rearrangement process is used, then laurolactam can be synthesized, but the process becomes very complex requiring multiple steps and extensive facilities
Solution Approach 1:
The patent combines the oxidation and Beckman rearrangement steps into a streamlined sequential process using solid acid catalysts, eliminating the need for separate extensive treatment facilities and reducing overall process complexity while maintaining high productivity
Solution Approach 2:
The patent extracts and eliminates the complex by-product treatment section from the conventional process by using a solid acid catalyst system that does not generate ammonium sulfate, thereby simplifying the overall facility requirements
3Productivity
If isopropylcyclohexane is used as solvent in oximation step, then the reaction can proceed, but the hydrophobic nature slows substance movement speed at oil-water interface requiring long reaction time
Solution Approach 1:
The patent changes the physical parameter of the reaction system by using a phase transfer catalyst that facilitates rapid mass transfer across the oil-water interface, overcoming the hydrophobic barrier of isopropylcyclohexane and enabling complete oximation within 1-2 hours
4Productivity
If multiple synthesis steps are used to produce cyclododecanone, then the process is thorough, but additional separation and dehydrogenation processes are required increasing complexity
Solution Approach 1:
The patent extracts and eliminates the separation and dehydrogenation steps from the conventional multi-step synthesis by using a selective oxidation process with solid acid catalysts that directly produces cyclododecanone with high selectivity, avoiding the formation of cyclododecene and cyclododecanol by-products
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 method achieves high conversion rates and selectivity for laurolactam, enabling a practical industrial process with high yield and purity, reducing the need for extensive facilities and simplifying the overall process.
Implementation Method 1
synthesizing epoxidized epoxidizing cyclododecene cyclododecane by (CDEN) with a catalyst
Implementation Method 2
synthesizing cyclododecanone by catalyzing the epoxidized cyclododecane
Implementation Method 3
synthesizing cyclododecanone oxime by performing ammoximation on the cyclododecanone
Implementation Method 4
a process of the Beckman rearrangement reaction is very complex and uses a concentrated sulfuric acid and a fuming sulfuric acid as catalysts
Data Source
AI summary
The present invention relates to a laurolactam preparation method and synthesis apparatus, and epoxidation and a rearrangement reaction are performed in the conversion of cyclododecene into cyclododecanone so that the preparation method can synthesize laurolactam having a higher purity with a higher selectivity and in a higher yield than a conventional preparation method.