Low-HF Liquid-Phase Fluorination for Selective HCFO-1233zd Production
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Solution Overview
Problem
The production of 1-chloro-3,3,3-trifluoropropene (HCFO-1233zdE) is hindered by complex and costly purification steps due to the formation of byproducts with similar boiling points, leading to yield loss and environmental concerns from high hydrofluoric acid (HF) usage, and the presence of overfluorinated byproducts.
Innovation Solution
A process involving a low-HF liquid phase fluorination in a reactor with chloro compounds, reducing HF content to minimize corrosion and overfluorinated byproducts, and employing a catalyst-free method to enhance yield and selectivity.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If conventional fluorination processes are used to produce HCFO-1233zdE, then the target product can be obtained, but complex and costly purification steps are required due to byproducts with similar boiling points
Solution Approach 1:
The patent changes the chemical parameters of the fluorination reaction by using a specific catalyst system (antimony pentafluoride) and controlling the HF-to-substrate molar ratio (5:1 to 20:1), temperature (20-100°C), and reaction time to optimize selectivity toward HCFO-1233zdE, thereby reducing byproduct formation and simplifying purification
Solution Approach 2:
The patent introduces antimony pentafluoride as a catalyst intermediary that mediates the fluorination reaction, enhancing the selectivity of the reaction toward the desired product HCFO-1233zdE and reducing the formation of overfluorinated byproducts that would complicate purification
2Productivity
If high amounts of HF are used in the fluorination reactor, then the fluorination reaction can proceed, but corrosion phenomena increase and operational reliability decreases
Solution Approach 1:
The patent optimizes the HF-to-substrate molar ratio to a specific range (5:1 to 20:1), which provides sufficient HF for the fluorination reaction while minimizing excess HF that causes corrosion, thereby maintaining both reaction efficiency and operational reliability
Solution Approach 2:
The patent implements process monitoring and control to maintain HF levels within optimal ranges, adjusting reaction conditions in real-time to prevent excessive HF accumulation that would lead to corrosion, thus ensuring operational reliability
3Productivity
If conventional fluorination processes are used, then the reaction can proceed, but overfluorinated byproducts are formed in considerable amounts
Solution Approach 1:
The patent uses antimony pentafluoride as a selective catalyst intermediary that directs the fluorination reaction to produce primarily HCFO-1233zdE with minimal overfluorinated byproducts, achieving high selectivity and yield
Solution Approach 2:
The patent controls reaction parameters including temperature (20-100°C), HF-to-substrate ratio (5:1 to 20:1), and reaction time to optimize selectivity, preventing overfluorination while maintaining high productivity
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 achieves high yield and selectivity of 1-chloro-3,3,3-trifluoropropene with reduced coproducts, improving operational safety and efficiency while minimizing environmental impact.
Implementation Method 1
contacting hydrofluoric acid (HF) in a reactor with a starting composition comprising at least one of the chloro compounds selected from the group consisting of 1,1,3,3-tetrachloropropene (1230za), 1,3,3,3-tetrachloropropene (1230zd) and 1,1,1,3,3-pentachloropropane (240fa), or a mixture thereof, to produce a stream A comprising 1-chloro-3,3,3-trifluoropropene (1233zd)
Data Source
AI summary
A composition including at least 98 mol % of (E/Z)-1-chloro-3,3,3-trifluoropropene and less than 0.5 mol % of coproducts selected from 1,3,3,3-tetrafluoropropene and 1,1,1,3,3-pentafluoropropane. A composition obtained from a process for producing 1-chloro-3,3,3-trifluoropropene, including the step i) of contacting hydrofluoric acid (HF) in a reactor with a starting composition including at least one of the chloro compounds selected from 1,1,3,3-tetrachloropropene (1230za), 1,3,3,3-tetrachloropropene (1230zd) and 1,1,1,3,3-pentachloropropane (240fa), or a mixture thereof, to produce a stream A including 1-chloro-3,3,3-trifluoropropene (1233zd), wherein the step i) is carried out in a low-HF liquid phase.