(Meth)acrylate Ester Production via Anhydride Extraction

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Solution Overview

Problem

Current methods for producing (meth)acrylate by reacting (meth)acrylic acid anhydride with an alcohol result in significant losses of (meth)acrylic acid anhydride, poor yield, and contamination issues due to hydrolysis and polymerization, leading to impurities and inefficient purification processes.

Innovation Solution

A method involving the reaction of fatty acid anhydride with (meth)acrylic acid to produce (meth)acrylic acid anhydride, followed by reacting the anhydride with an alcohol and recovering (meth)acrylic acid through distillation, while using a basic compound to hydrolyze remaining anhydride, all conducted at elevated temperatures to minimize losses and maximize yield and purity.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Manufacturing precision

If (meth)acrylic acid anhydride is neutralized and washed with alkaline aqueous solution for purification, then purity is improved, but (meth)acrylic acid anhydride is hydrolyzed and large quantity of washing-wastewater is generated

Engineering Contradiction:
Improvepurity of (meth)acrylic acid anhydrideVSAvoidloss of (meth)acrylic acid anhydride
Core Design Contradiction:
Manufacturing precisionVSLoss of substance

Solution Approach 1:

The patent extracts and removes the harmful impurity (carboxylic acid) from the reaction mixture by reacting it with an organic base to form a soluble salt, which is then separated from the organic phase containing (meth)acrylic acid anhydride. This eliminates the need for aqueous washing that causes hydrolysis and waste water generation.

Inventive Principle:
Principle #2Taking out (Extraction)

Solution Approach 2:

The patent introduces an organic base as an intermediary substance to neutralize the carboxylic acid impurity. The organic base forms a soluble salt with the acid that can be easily separated, serving as a mediator that removes the harmful acid without requiring water that would cause hydrolysis.

Inventive Principle:
Principle #24Intermediary (Mediator)

2Manufacturing precision

If fractional distillation is used to purify (meth)acrylic acid anhydride, then purity is improved, but (meth)acrylic acid anhydride is lost in initial distillate or reaction vessel and polymerization risk increases

Engineering Contradiction:
Improvepurity of (meth)acrylic acid anhydrideVSAvoidyield of (meth)acrylic acid anhydride
Core Design Contradiction:
Manufacturing precisionVSProductivity

Solution Approach 1:

The patent extracts the carboxylic acid impurity from the (meth)acrylic acid anhydride through chemical reaction with an organic base, forming a separable salt. This removes the need for fractional distillation that causes loss of material in distillate and reaction vessel residues.

Inventive Principle:
Principle #2Taking out (Extraction)

Solution Approach 2:

The patent converts the harmful carboxylic acid impurity into a beneficial form by reacting it with an organic base to form a soluble salt. This transformation allows easy separation and removal of the impurity without the material losses associated with distillation, while the salt can potentially be reused to regenerate the acid.

Inventive Principle:
Principle #22Blessing in disguise (Convert harm into benefit)

3Productivity

If crude (meth)acrylic acid anhydride containing Michael addition products is reacted with alcohol, then production efficiency is improved, but yield under alcohol standard deteriorates and ester impurities are included

Engineering Contradiction:
Improveproduction efficiency of (meth)acrylateVSAvoidpurity of (meth)acrylate product
Core Design Contradiction:
ProductivityVSManufacturing precision

Solution Approach 1:

The patent performs preliminary purification of (meth)acrylic acid anhydride by removing carboxylic acid impurities through reaction with an organic base before the alcoholysis reaction. This preliminary action prevents the formation of Michael addition products and ester impurities during the subsequent reaction with alcohol, ensuring high yield and purity.

Inventive Principle:
Principle #10Preliminary action

Solution Approach 2:

The patent applies preliminary anti-action by removing the carboxylic acid impurity that would otherwise cause harmful side reactions (Michael addition) during the alcoholysis process. By eliminating the acid before reaction with alcohol, the patent prevents the formation of unwanted ester impurities and maximizes the yield of desired (meth)acrylate.

Inventive Principle:
Principle #9Preliminary anti-action

4Ease of operation

If one component is added with surplus amount for ease of purification, then ease of operation is improved, but loss of the other component increases

Engineering Contradiction:
Improveease of purificationVSAvoidloss of (meth)acrylic acid anhydride or alcohol
Core Design Contradiction:
Ease of operationVSLoss of substance

Solution Approach 1:

The patent extracts and removes the carboxylic acid impurity through chemical reaction with an organic base, forming a separable salt. This eliminates the need to use surplus of either reactant for purification purposes, allowing stoichiometric or near-stoichiometric amounts to be used without material loss.

Inventive Principle:
Principle #2Taking out (Extraction)

Solution Approach 2:

The patent introduces an organic base as an intermediary that selectively reacts with the carboxylic acid impurity without consuming the main reactants ((meth)acrylic acid anhydride or alcohol). This intermediary approach enables easy removal of impurities without requiring surplus addition of reactants, thus avoiding loss of valuable materials.

Inventive Principle:
Principle #24Intermediary (Mediator)

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 effectively reduces (meth)acrylic acid anhydride losses, enhances the yield and purity of (meth)acrylate, and facilitates efficient recovery of (meth)acrylic acid, resulting in a high-grade (meth)acrylate product with improved purification efficiency.

Implementation Method 1

a process of hydrolyzing remaining-(meth)acrylic acid anhydride by addition of at least one kind of a basic compound selected from hydroxides, carbonates, bicarbonates, and oxides of alkali metals or alkaline earth metals to the reaction liquid containing the (meth)acrylate

Methodology Applied
Scientific EffectHydrolysis: Hydrolysis

Implementation Method 2

a process of recovering (meth)acrylic acid by distillation

Methodology Applied
Scientific EffectDistillation: Distillation

Data Source

PatentUS8859804B2Method for producing a (meth)acrylate
Publication Date: 2014.10.14 MITSUBISHI CHEM CORP
  • US8859804B2 patent drawing
  • US8859804B2 patent drawing
  • US8859804B2 patent drawing

AI summary

Disclosed is a method for producing a (meth)acrylate ester wherein a high purity (meth)acrylate ester is obtained with a high yield, with a reduced loss of (meth)acrylic acid anhydride. In the method, (meth)acrylic acid is recovered with a high yield, and the (meth)acrylate ester is purified easily. Specifically disclosed is a method for producing a (meth)acrylate ester which comprises: (1) a step of producing (meth)acrylic acid anhydride by reacting a specific fatty acid anhydride and (meth)acrylic acid, while removing a by-produced fatty acid; (2) a step of obtaining a (meth)acrylate ester by reacting an alcohol and unpurified (meth)acrylic acid anhydride obtained in step (1) preferably at a temperature not less than 90° C.; and (3) a step of recovering (meth)acrylic acid by distillation preferably at a temperature not less than 90° C. The method may also comprise a step of heating or distilling the reaction liquid obtained in step (2) at a temperature not less than 90° C.