Methanol Carbonylation to Ethanol via Segmented Reactors
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Solution Overview
Problem
The production of ethanol from methanol and syngas is hindered by the presence of significant amounts of hydrogen in the carbonylation reactor, which inhibits the carbonylation reaction.
Innovation Solution
A process involving the reaction of methanol and carbon monoxide to produce methyl acetate, followed by hydrogenolysis and hydrogenation using separated hydrogen to produce ethanol, with specific conditions and catalysts to achieve a product comprising at least 25 mole % methyl acetate and subsequent conversion to ethanol.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Device complexity
If hydrogen is not separated from synthesis gas prior to carbonylation reaction, then the process is simpler, but the carbonylation reaction is significantly hindered
Solution Approach 1:
The process is divided into distinct stages: first performing carbonylation reaction to produce methyl acetate and acetic acid, then separately performing hydrogenation in a second reactor. This segmentation allows the carbonylation step to proceed without hydrogen inhibition, while hydrogen is added later in controlled amounts for the hydrogenation step, thus resolving the contradiction between process simplicity and reaction efficiency
Solution Approach 2:
The carbonylation reaction is performed first to establish the product distribution (methyl acetate and acetic acid) before introducing hydrogen for hydrogenation. This preliminary action ensures that the carbonylation proceeds efficiently without hydrogen interference, while still achieving the desired ethanol production through subsequent hydrogenation
2Quantity of substance
If significant amounts of hydrogen are present in the carbonylation reactor, then hydrogen availability is maintained, but the carbonylation of methanol with carbon monoxide is significantly hindered
Solution Approach 1:
The reaction process is segmented into two separate reactors: the first reactor performs carbonylation without hydrogen to avoid inhibition, while the second reactor performs hydrogenation with sufficient hydrogen supply. This spatial segmentation resolves the contradiction by allowing each reaction to proceed under its optimal conditions
Solution Approach 2:
Methyl acetate and acetic acid serve as intermediary products that bridge the carbonylation and hydrogenation steps. These intermediaries are formed in the first reactor without hydrogen, then transferred to the second reactor where hydrogen is introduced for conversion to ethanol, thus mediating between hydrogen availability and carbonylation 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 process effectively converts methanol to ethanol with high yields, overcoming the hydrogen inhibition issue and achieving efficient ethanol production from syngas-derived carbon monoxide and hydrogen.
Implementation Method 1
The reaction of methanol and carbon monoxide is a carbonylation reaction, which creates a carbon-carbon (C—C) bond
Implementation Method 2
The methyl acetate and ethyl acetate then are hydrogenated in the presence of a hydrogenation catalyst to produce ethanol
Implementation Method 3
the carbonylation of the methanol with carbon monoxide in the presence of a carbonylation catalyst to produce methyl acetate
Data Source
AI summary
A process for converting methanol to ethanol which comprises reacting methanol and carbon monoxide in the presence of a catalyst to produce a product comprising at least 25 mole % methyl acetate and, in some instances, acetic acid. The acetic acid then is reacted with at least one alcohol to produce at least one acetate selected from methyl acetate, ethyl acetate, and butyl acetate. The at least one acetate (if produced) and the methyl acetate produced as a result of reacting methanol and carbon monoxide then are hydrogenated to produce ethanol. Syngas may be produced from biomass to produce all or a portion of the methanol, hydrogen, and carbon monoxide requirements for the process.