Methanol Removal Column for Bisphenol A Production
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Solution Overview
Problem
The production process of bisphenol A is limited by the presence of methanol as an impurity in acetone, which acts as a catalyst poison, leading to reduced catalyst lifespan and low conversion rates, and high energy consumption in separation processes, affecting the quality and productivity of bisphenol A.
Innovation Solution
A removal unit comprising a removal column with a supply part and overhead purge part for separating methanol and acetone, and a bottom recirculation part that recirculates the removed methanol and acetone to the purification unit, allowing for improved control of the acetone conversion rate and selectivity of bisphenol A without being limited by the dehydration column capacity.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a distillation tower is installed to remove methanol from acetone, then methanol separation is achieved, but energy consumption increases due to the large number of stages required
Solution Approach 1:
A dehydration column is introduced as an intermediary unit between the acetone storage tank and the bisphenol A production system. This column removes water from acetone through distillation, preventing methanol formation and eliminating the need for a separate methanol removal tower, thereby reducing overall energy consumption while maintaining product purity
Solution Approach 2:
Water is removed from acetone in advance through the dehydration column before the acetone enters the bisphenol A production system. This preliminary dehydration prevents methanol formation during subsequent reactions, avoiding the need for later methanol removal steps and reducing total energy requirements
2Productivity
If the amount of acetone is increased to increase bisphenol A production, then production amount increases, but catalyst lifespan decreases due to methanol acting as catalyst poison
Solution Approach 1:
The dehydration column acts as a protective intermediary that removes water from acetone before it enters the reaction system. This prevents methanol formation that would otherwise poison the catalyst, allowing sustained high-level production without catalyst deactivation
Solution Approach 2:
Water removal is performed in advance through the dehydration column, preventing methanol formation before it can affect the catalyst. This preliminary protective action enables continuous high-volume acetone processing without catalyst lifespan reduction
3Stability of the object's composition
If the amount of phenol is increased to prevent relative content reduction, then phenol to acetone ratio is maintained, but conversion rate of acetone remains low due to increased residence time
Solution Approach 1:
The dehydration column serves as a preparative intermediary that conditions the acetone feedstock by removing water. This improves the quality of acetone entering the reactor, enabling better conversion efficiency even when phenol quantity is increased to maintain proper stoichiometric ratios
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
The solution effectively reduces methanol accumulation, improves catalyst lifespan, and increases bisphenol A productivity by efficiently removing methanol and acetone, while reducing energy consumption and enhancing the selectivity of bisphenol A.
Implementation Method 1
the separation between acetone and methanol using distillation requires a large number of stages
Implementation Method 2
a dehydration column for removing unreacted acetone and water from a reaction product discharged from the reaction unit
Implementation Method 3
an acetone recovery column connected to an unreacted acetone discharge line discharged from an upper end of the dehydration column, for recovering acetone by removing the acetone from the water-rich fraction
Data Source
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AI summary
Provided is a removal unit of methanol and acetone which is provided in a system including a production system of phenol having a decomposition reaction unit and a purification unit, and a production system of bisphenol A having a reaction unit and a concentration unit. The removal unit includes a removal column, a supply part provided in the midsection of the removal column, an overhead purge part in which methanol and acetone are removed, and a bottom recirculation part recirculated to the purification unit, wherein the supply part includes a purification unit discharge part in which methanol, acetone, and water are included, and a concentration unit discharge part in which phenol, acetone, and water are included. The removal unit may be included in the production system of phenol and bisphenol A, in which case the productivity of bisphenol A may be improved and the lifespan of a catalyst in a reactor may be improved.