Liquid-Phase Decarboxylative Ketonization With Continuous Ketone Distillation
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Solution Overview
Problem
Existing processes for producing ketones from C2-C8 carboxylic acids and derivatives are inefficient, requiring high temperatures, complex equipment, and face challenges with pressure management and catalyst compatibility, especially when producing lower-boiling ketones.
Innovation Solution
A decarboxylative ketonization process in the liquid phase using a catalyst and solvent with a boiling point higher than the reaction temperature, allowing continuous distillation of formed ketones, and utilizing bio-based materials to produce ketones with high bio-based carbon content.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If gas phase process is used for ketone production, then equipment sophistication and operating cost increase, but productivity decreases
Solution Approach 1:
The patent changes the phase parameter from gas phase to liquid phase, operating at lower temperatures (below boiling point of ketone product) to achieve higher productivity with simpler equipment. The liquid phase process allows for easier heat transfer and simpler equipment design compared to gas phase operations.
Solution Approach 2:
The patent introduces a liquid solvent as an intermediary medium to enable the reaction to proceed in liquid phase. This solvent facilitates the reaction at lower temperatures and enables continuous operation with simpler equipment, avoiding the need for complex high-temperature gas phase equipment.
2Productivity
If liquid phase process at high temperature is used, then ketone production is achieved, but pressure build-up occurs requiring autoclave and complex pressure management
Solution Approach 1:
The patent changes the temperature parameter to operate below the boiling point of the ketone product, allowing the reaction to proceed in liquid phase without generating excessive pressure. This parameter change eliminates the need for autoclave and complex pressure management systems.
Solution Approach 2:
The patent utilizes phase transition of the ketone product (distillation) to separate it from the reaction mixture. By operating below the ketone's boiling point and continuously removing the product via distillation, the system maintains liquid phase reaction conditions without pressure build-up.
3Productivity
If process temperature is increased above ketone boiling point, then decarboxylation is facilitated, but product separation becomes difficult and pressure control is required
Solution Approach 1:
The patent optimizes the temperature parameter to operate just below the ketone's boiling point, providing sufficient thermal energy for decarboxylation while maintaining liquid phase conditions that facilitate easy product separation via distillation without requiring pressure control.
Solution Approach 2:
The patent implements continuous distillation of the ketone product throughout the reaction process. This continuous removal of product maintains favorable conditions for decarboxylation while continuously separating the product, eliminating the need for pressure control and simplifying 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
The process avoids pressure build-up, simplifies work-up, and enables efficient production of high-purity ketones with bio-based carbon content, compatible with cost-effective catalysts and standard equipment, enhancing productivity and catalyst compatibility.
Implementation Method 1
a composition (C) comprising at least one metal compound or at least an elementary metal as catalyst
Implementation Method 2
a solvent having a boiling point at least 40° C. higher than the process temperature
Implementation Method 3
the formed ketone is continuously distilled off
Data Source
AI summary
The present invention relates to a process for the manufacture of ketones though a decarboxylative ketonization process of C2-C8 carboxylic acids, C2-C8 carboxylic acid derivatives or mixtures thereof, in the liquid phase. The present invention further relates to ketones susceptible of being produced by the process of the invention.