Lewis Base Demulsifier for Emulsion Control in Liquid-Liquid Extraction
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Solution Overview
Problem
The recovery of diphosphite-containing compounds from hydrocyanation reaction product mixtures is hindered by the formation of emulsion phases and rag layers in multistage countercurrent liquid-liquid extractors, which impede phase separation and catalyst extraction efficiency.
Innovation Solution
The process involves adding a Lewis base to the mixing section of the multistage countercurrent liquid-liquid extractor, enhancing the settling of emulsion phases and reducing the formation of rag layers, thereby improving the separation of diphosphite-containing compounds into the light phase and increasing their recovery efficiency.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If multistage countercurrent liquid-liquid extraction is used to recover diphosphite-containing compounds, then extraction efficiency is improved, but emulsion phases and rag layers form which impede phase separation
Solution Approach 1:
A demulsifier agent is introduced as an intermediary substance to break the emulsion phases formed during extraction. The demulsifier selectively interacts with the emulsion droplets, causing coalescence and separation of the otherwise stable emulsion, thereby restoring phase separation capability without affecting the extraction efficiency of diphosphite-containing compounds
Solution Approach 2:
The patent modifies operational parameters including temperature, agitation speed, and demulsifier dosage to control emulsion stability and promote phase separation. By optimizing these parameters, the system maintains high extraction efficiency while preventing problematic emulsion formation that would otherwise halt the continuous extraction process
2Productivity
If continuous extraction operation is maintained, then productivity is improved, but rag accumulates at the interface requiring process shutdown for removal
Solution Approach 1:
The system incorporates automated rag removal mechanisms and self-cleaning features that operate continuously without requiring process shutdown. The demulsifier treatment prevents rag formation at the interface, and automated skimming devices continuously remove any rag that does form, allowing the extraction process to maintain continuous operation without manual intervention
Solution Approach 2:
The demulsifier is added in advance to prevent rag formation rather than treating accumulated rag after the fact. This preliminary action of emulsion breaking prevents the conditions that lead to rag accumulation, eliminating the need for periodic shutdowns for rag removal and maintaining continuous productivity
3Quantity of substance
If emulsion phases are allowed to accumulate, then extraction capacity is improved, but settling time increases and separation efficiency decreases
Solution Approach 1:
The demulsifier agent acts as a mediator that accelerates the settling process by breaking emulsion stability. It enables the system to handle high extraction capacities with rapid phase separation, converting what would be a time-consuming settling process into a fast operation that does not bottleneck the overall extraction throughput
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 addition of a Lewis base significantly reduces the size and formation rate of emulsion phases and rag layers, leading to enhanced settling and increased recovery of diphosphite-containing compounds, thereby improving the extraction efficiency and preventing process shutdowns.
Implementation Method 1
a complex of said Lewis acid and said Lewis base
Implementation Method 2
contacting the feed mixture with extraction solvent in the multistage countercurrent liquid-liquid extractor
Implementation Method 3
a light phase separates from a heavy phase in the settling section
Data Source
Figure 1~3
Figure 4
AI summary
Disclosed herein are methods for recovering diphosphite-containing compounds from mixtures comprising organic mononitriles and organic dinitriles, using liquid-liquid extraction. Also disclosed are treatments to enhance extractability of the diphosphite-containing compounds.