(Meth)acrylate Production System with Reflux and Liquid Separation
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Solution Overview
Problem
Current methods for producing (meth)acrylates through transesterification struggle with efficiently collecting and reusing the remaining (meth)acrylate used as a raw material, solvent, and alcohol by-products, leading to inefficiencies and waste in the reaction system.
Innovation Solution
A system comprising a reactor with a distillation column and a distillation apparatus, where condensate is refluxed and separated into layers, allowing for the efficient collection and reuse of (meth)acrylate, solvent, and alcohol, without the need for reduced pressure, thereby optimizing the production process.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Loss of substance
If conventional distillation methods are used to separate methanol from methyl (meth)acrylate, then methanol can be removed from the reaction mixture, but the remaining methyl (meth)acrylate in the reactor cannot be collected
Solution Approach 1:
Instead of continuing to distill under the same conditions that removed methanol, the patent inverts the approach by switching to reduced pressure distillation after the reaction. This allows the remaining methyl (meth)acrylate to be collected at lower temperatures and pressures, preventing polymerization while enabling complete recovery of the product that would otherwise remain in the reactor.
2Productivity
If reduced pressure distillation is used to collect remaining (meth)acrylate, then collection efficiency improves, but polymerization and odor diffusion occur
Solution Approach 1:
The patent applies preliminary action by adding a polymerization inhibitor to the reaction mixture before the distillation process. This inhibitor is present during both the conventional distillation phase and the subsequent reduced pressure collection phase, preventing polymerization from occurring even when the (meth)acrylate is heated under reduced pressure, thus enabling efficient collection without the harmful effects of polymerization and odor.
3Productivity
If conventional distillation is used to remove by-products, then transesterification reaction proceeds efficiently, but remaining raw materials and by-products cannot be reused
Solution Approach 1:
The patent implements discarding and recovering by first using conventional distillation to remove methanol and other by-products during the reaction phase, then switching to reduced pressure distillation to recover the remaining methyl (meth)acrylate. The recovered material is collected and can be reused in subsequent reactions, transforming what would have been waste into a recoverable resource and improving overall process efficiency.
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 efficient collection and reuse of (meth)acrylate and its by-products, enhancing industrial productivity and reducing waste, while preventing polymerization and odor diffusion, thus improving the overall production efficiency and environmental impact.
Implementation Method 1
a reactor A having a distillation column and a distillation apparatus B having a distillation column
Implementation Method 2
a temperature not lower than the azeotropic temperature of the alkyl alcohol which is generated as a by-product and the azeotropic solvent, and a temperature not higher than a temperature 2°C higher than the azeotropic temperature
Implementation Method 3
the condensing apparatus is connected with the upper part of the distillation column through a switching apparatus with a pipe for refluxing a part of a condensate obtained in the condensing apparatus
Implementation Method 4
using an azeotropic solvent which forms an azeotropic mixture with methanol
Implementation Method 5
separating the remaining condensate into two layers, supplying the upper layer of the two layers to a middle stage of the distillation column
Data Source
Figure 1
Figure 2
AI summary
A (meth)acrylate production system having a reactor (A1) provided with a distillation column (2) and a distillation apparatus (B3) provided with a distillation column (4). A condensing apparatus (6) is provided at the top of the distillation column (2). The condensing apparatus (6) and a switching apparatus (7) are connected via a pipe (5b), the switching apparatus (7) and the top of the distillation column (2) are connected via a pipe (5c), the switching apparatus (7) and a liquid separation apparatus (8) are connected via a pipe (5d), the top of the liquid separation apparatus (8) and the distillation column (2) are connected via pipe (5e), the bottom of the liquid separation apparatus (8) and the distillation apparatus (B3) are connected via a pipe (5f), the top of the distillation column (4) is connected with a condensing apparatus (9) via a pipe (10a), the condensing apparatus (9) and a switching apparatus (11) are connected via a pipe (10b), the switching apparatus (11) and the top of the distillation column (4) are connected via a pipe (10c), the switching apparatus (11) and a recovery unit (12) are connected via a pipe (10d), and the bottom of the distillation apparatus (B3) is connected with the pipe (5d) between the switching apparatus (7) and the liquid separation apparatus (8) via a pipe (10e).