Membrane Dehydration for Alkyl Methacrylate Purification
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Solution Overview
Problem
The production of C4-C10 alkyl (meth)acrylates faces challenges in efficiently eliminating water and recycling unreacted reagents while dealing with complex and costly purification processes, especially due to the presence of azeotropic mixtures and energy-intensive distillations.
Innovation Solution
Incorporating a membrane separation dehydration step using pervaporation or vapor permeation, specifically with inorganic or hydrophilic membranes, to effectively remove water from streams generated during the purification of alkyl (meth)acrylates, allowing for the treatment of aqueous streams outside previously defined concentration ranges and reducing energy consumption.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If distillation and extraction treatments are used to purify the reaction mixture, then the desired ester can be obtained meeting commercial specifications, but the process becomes complex and energy-consuming
Solution Approach 1:
The patent extracts water from the reaction mixture using a membrane separator that selectively removes water through a membrane barrier. This extraction approach replaces traditional energy-intensive distillation and extraction treatments, achieving the same purification goal without the associated high energy consumption and process complexity.
Solution Approach 2:
The patent replaces the mechanical/thermal separation systems (distillation columns, extraction equipment) with a membrane-based separation system. This substitution uses selective permeation through membranes rather than thermal energy input, significantly reducing energy consumption while maintaining product purity.
2Manufacturing precision
If traditional distillation and extraction treatments are applied, then water and impurities can be removed, but the process complexity increases due to azeotropic mixtures
Solution Approach 1:
The membrane separator selectively extracts water from complex reaction mixtures containing azeotropic components. This single extraction step replaces multiple complex separation stages required by traditional methods, simplifying the overall process while effectively removing water and impurities.
Solution Approach 2:
The patent changes the separation mechanism from thermal-based (distillation) to membrane-based separation. This parameter change allows for selective water removal through membrane permeation, avoiding the complications of azeotropic behavior that plague traditional distillation processes.
3Manufacturing precision
If membrane separation dehydration is applied to streams with well-defined concentration ranges, then water elimination is effective and selectivity is good, but the process is limited to specific concentration ranges
Solution Approach 1:
The patent makes the membrane separation process universal by demonstrating its effectiveness across multiple concentration ranges and different stream compositions. The same membrane technology is applied to various streams (reaction mixture, intermediate streams, final product streams), making the process adaptable and versatile rather than limited to specific concentration ranges.
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 approach enables the production of high-selectivity alkyl (meth)acrylates with reduced energy costs and minimized installation costs, allowing for the treatment of aqueous streams at higher velocities and potentially eliminating the need for downstream purification columns, thereby enhancing productivity and reducing energy consumption.
Implementation Method 1
a step of membrane separation dehydration applied to at least one of the following streams: the stream subjected to the final distillation leading to the recovery of the purified (meth)acrylic ester, the aqueous stream originating from the settling out of the reaction mixture, or the stream resulting from the distillation of the light by-products present in the reaction mixture
Implementation Method 2
the membrane separation dehydration is a dehydration by pervaporation or by vapor permeation
Data Source
AI summary
The invention relates to a method for producing alkyl (meth)acrylate comprising a linear or branched alkyl chain comprising 4 to 10 carbon atoms, by direct esterification of (meth)acrylic acid with a linear or branched alcohol comprising 4 to 10 carbon atoms in the presence of a catalyst, leading to formation of a reaction mixture comprising the desired ester, unreacted acid and alcohol, light by-products, and heavy by-products. The mixture undergoes purification treatment by separation means to obtain purified alkyl (meth)acrylate. The purification treatment comprises a step of membrane separation dehydration applied to at least one of the following: the stream subjected to the final distillation leading to the recovery of the purified (meth)acrylic ester, the aqueous stream originating from the settling out of the reaction mixture, or the stream resulting from the distillation of the light by-products present in the reaction mixture.