Dialkyl Maleate Electrohydrodimerization With Low Cell Voltage
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Solution Overview
Problem
Existing processes for producing tetraalkyl 1,2,3,4-butanetetracarboxylates are either economically unviable or unsustainable on an industrial scale.
Innovation Solution
An electrochemical process using boron-doped diamond electrodes for electrohydrodimerization of dialkyl maleates in the presence of a monohydric alcohol and a conducting salt, optimizing parameters such as concentration, temperature, and current density to produce tetraalkyl 1,2,3,4-butanetetracarboxylates efficiently.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If conventional electrochemical processes are used for producing tetraalkyl 1,2,3,4-butanetetracarboxylates, then the production can be achieved, but the process cannot be operated economically or sustainably on an industrial scale
Solution Approach 1:
The patent applies parameter changes by optimizing key process variables including current density (0.1-10 mA/cm²), temperature (20-80°C), concentration of dialkyl maleate (0.1-5 M), and composition of the supporting electrolyte. These parameter optimizations enable the electrochemical process to achieve economic viability and sustainability by reducing energy consumption while maintaining high production efficiency
2Ease of manufacture
If conventional electrochemical processes are used for producing tetraalkyl 1,2,3,4-butanetetracarboxylates, then the production can be achieved, but the process cannot be operated economically or sustainably on an industrial scale
Solution Approach 1:
The patent implements sustainability improvements through parameter changes including optimizing current density to reduce energy waste, controlling temperature (20-80°C) to minimize thermal energy loss, and selecting appropriate supporting electrolytes (0.1-1 M concentration) to enhance electrical conductivity and reduce electrical energy consumption, thereby making the process industrially sustainable
3Ease of operation
If conventional electrode materials are used in the electrochemical process, then the process can be operated, but higher cell voltage and energy consumption result
Solution Approach 1:
The patent achieves lower cell voltage and energy consumption by optimizing operational parameters including current density (0.1-10 mA/cm²), temperature (20-80°C), and electrolyte composition. These parameter changes reduce the electrical resistance and overpotential, enabling efficient operation with reduced energy input while maintaining process operability
4Ease of operation
If conventional electrode materials are used in the electrochemical process, then the process can be operated, but higher cell voltage and energy consumption result
Solution Approach 1:
The patent reduces energy consumption through optimized parameter settings including current density (0.1-10 mA/cm²) that minimizes resistive heating, temperature control (20-80°C) that reduces thermal energy loss, and supporting electrolyte composition (0.1-1 M concentration) that enhances ionic conductivity, thereby enabling efficient energy utilization while maintaining operational ease
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 lower cell voltage and energy consumption, enabling an economically viable and sustainable production of tetraalkyl 1,2,3,4-butanetetracarboxylates with high yield and selectivity.
Implementation Method 1
The process comprises the electrohydrodimerization of dialkyl maleates containing alkyl groups having 1 to 6 carbon atoms in a reactant solution containing an alcohol and a conducting salt
Implementation Method 2
a reactant solution comprising dialkyl maleates containing alkyl groups having 1 to 6 carbon atoms, preferably alkyl groups having 2 to 5 carbon atoms, particularly preferably having 5 carbon atoms, at least one monohydric alcohol having 1 to 6 carbon atoms, preferably having 2 to 5 carbon atoms, particularly preferably having 5 carbon atoms, and a conducting salt
Data Source
AI summary
An electrochemical process produces tetraalkyl 1,2,3,4-butanetetracarboxylates having alkyl groups with 1 to 6 carbon atoms. The process employs an electrohydrodimerization of dialkyl maleates having alkyl groups having 1 to 6 carbon atoms in a reactant solution with an alcohol and a conducting salt.