Methacrylic Acid Process Raw Material Flexibility
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Solution Overview
Problem
Current methacrylic acid production processes are inflexible due to reliance on single raw material sources, leading to instability in production when raw material availability or costs fluctuate, and generate significant wastewater containing organic compounds that are difficult to treat and recover.
Innovation Solution
A process that oxidizes a methacrolein mixture from diverse sources, allowing switching between C4 and C2-based raw materials and incorporating steps for the recovery of methacrylic acid from high boiler phases and wastewater, enabling improved yield and waste management.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a single raw material source (C2 or C4 basis) is used for methacrylic acid production, then the production process is simple and stable, but the process becomes inflexible when raw material availability or costs fluctuate
Solution Approach 1:
The patent implements a dual raw material basis system that can process both C2-based (ethylene) and C4-based (isobutylene, tert-butyl alcohol, methyl tert-butyl ether) starting materials through the same production facility. The oxidation unit is designed to handle different feedstocks, enabling the plant to switch between raw material sources based on availability and cost, thereby achieving both production stability and raw material flexibility
2Object-generated harmful factors
If waste water is combusted to remove organic compounds, then organic compounds are eliminated, but energy input is high and valuable compounds are lost
Solution Approach 1:
Instead of combusting the waste water to eliminate organic compounds, the patent recovers valuable organic compounds (methacrylic acid, acrylic acid, acetic acid, propionic acid) from the waste water through extraction and distillation processes. The recovered compounds are reused in the production process or sold as products, converting the harmful waste stream into a beneficial resource and significantly reducing energy consumption compared to combustion
Solution Approach 2:
The patent implements a recovery system that extracts and recovers valuable organic compounds from the waste water generated during methacrylic acid production. The extraction unit separates organic compounds from the aqueous phase, and subsequent distillation purifies these compounds for reuse or sale, preventing their complete disposal through combustion and reducing both energy consumption and material loss
3Manufacturing precision
If extraction agents are used to separate methacrylic acid from aqueous phase, then separation efficiency is improved, but large amounts of wastewater containing organic compounds are generated
Solution Approach 1:
The patent implements a recovery system that extracts and recovers valuable organic compounds from the waste water generated during methacrylic acid production. The extraction unit separates organic compounds from the aqueous phase, and subsequent distillation purifies these compounds for reuse or sale, preventing their complete disposal through combustion and reducing both energy consumption and material loss
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 process enhances the flexibility and efficiency of methacrylic acid production by allowing raw material switching and recovering valuable compounds from waste streams, reducing environmental impact and operational costs.
Implementation Method 1
a1) gas phase oxidation of at least one C4 compound to obtain a reaction phase comprising methacrylic acid
Implementation Method 2
a2) quenching of the reaction phase to obtain a crude aqueous phase comprising methacrylic acid
Implementation Method 3
introduced into a solvent extraction column, in order to extract and separate methacrylic acid by means of suitable extraction agents
Implementation Method 4
The separated methacrylic acid is further purified, for example by distillation, to separate high-boiling impurities
Data Source
Figure 1
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Figure 3~4
AI summary
The invention relates to a process for preparation of at least one of methacrylic acid and a methacrylic acid ester, comprising the process stepsgas phase oxidation of at least one C4 compound, quenching of the reaction phase, separation and purification of the obtained methacrylic acid and optionally esterification,wherein the C4 compound is a methacrolein comprising mixture, originatingfrom at least two different methacrolein sources, a first methacrolein source being a feed stream obtained by the heterogeneously catalysed gas phase oxidation of isobutylene or tert-butyl alcohol or isobutylaldehyde or a mixture of two or more thereof,a second methacrolein source being a feed stream obtained by the reaction of propionaldehyde with a C1 extending agent,preferably formaldehyde, and where said methacrolein can be obtained either completely from the first methacrolein source, or completely from the second methacrolein source or from any mixture of both.