Moving Material Acylation with Counter-Current HCl Removal
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Existing acylation processes, such as those described in WO 2012/066015, do not achieve optimal hydrophobicity and water-impermeability in acylated substrates, as they fail to maintain sufficient concentration of fatty acid chloride during the acylation reaction, leading to unsatisfactory hydrophobicity properties.
Innovation Solution
A chromatogenic acylation process and device that maintains a gaseous atmosphere with a fatty acid chloride concentration equal to its saturating vapour pressure, using a counter-current stream to entrain hydrochloric acid and adjust parameters like scrolling speed and temperature to optimize the reaction.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Object-generated harmful factors
If a stream of gaseous composition is used to flush the hydroxylated substrate and entrain excess grafting reagent and hydrochloric acid, then hydrochloric acid removal is improved, but fatty acid chloride concentration decreases leading to lower hydrophobicity
Solution Approach 1:
The acylation chamber is divided into multiple zones with different functions: a reaction zone where fatty acid chloride is introduced and maintained at saturating concentration for optimal acylation, and a separate flushing zone where gaseous stream removes hydrochloric acid. This spatial segmentation allows simultaneous optimization of both reaction efficiency and harmful byproduct removal.
Solution Approach 2:
Different regions of the acylation chamber are provided with different gaseous composition qualities: the reaction zone maintains high fatty acid chloride concentration for optimal acylation, while the flushing zone uses higher flow rates to entrain hydrochloric acid. The counter-current arrangement ensures that the flushing action occurs where hydrochloric acid concentration is highest, without significantly reducing fatty acid chloride concentration in the reaction zone.
2Object-generated harmful factors
If the gaseous stream flow rate is increased to improve hydrochloric acid removal, then hydrochloric acid entrainment is improved, but reaction efficiency decreases due to lower fatty acid chloride concentration
Solution Approach 1:
The system employs dynamic control of gaseous stream flow rates to optimize both hydrochloric acid removal and fatty acid chloride concentration. The counter-current arrangement allows the flushing stream to enter at the outlet end and move opposite to the substrate motion, creating optimal conditions for hydrochloric acid entrainment while maintaining reaction efficiency in the upstream zone.
Solution Approach 2:
The counter-current gaseous stream acts as an intermediary that selectively removes hydrochloric acid without significantly affecting fatty acid chloride concentration in the reaction zone. The stream serves as a transport medium that carries away harmful byproducts while allowing the saturating concentration of fatty acid chloride to be maintained in the reaction zone.
3Quantity of substance
If fatty acid chloride concentration is maintained at saturating vapour pressure for optimal acylation, then hydrophobicity is improved, but hydrochloric acid accumulation increases
Solution Approach 1:
The system maintains continuous introduction of fatty acid chloride at saturating concentration throughout the acylation process, ensuring optimal reaction conditions are constantly maintained. Simultaneously, a continuous counter-current gaseous stream removes hydrochloric acid as it is formed, preventing accumulation and allowing the acylation reaction to proceed efficiently without equilibrium limitations.
Solution Approach 2:
The system employs monitoring of fatty acid chloride concentration and hydrochloric acid removal efficiency to dynamically adjust operating parameters. The counter-current arrangement provides inherent feedback control where the effectiveness of hydrochloric acid removal influences the overall reaction rate and product quality.
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 process achieves hydrophobic and water-impermeable acylated materials with improved hydrophobicity and water-repellency, suitable for industrial-scale production, without the need for organic solvents or catalysts, and allows for continuous monitoring and adjustment of reaction conditions.
Implementation Method 1
a gaseous atmosphere with a fatty acid chloride concentration equal to its saturating vapour pressure
Implementation Method 2
acylation by chromatogenic synthesis
Implementation Method 3
a stream of gaseous composition flowing from downstream to upstream in said acylation chamber counter-currentwise relative to said scrolled hydroxylated material
Implementation Method 4
to entrain the excess grafting reagent and the hydrochloric acid formed
Implementation Method 5
the gaseous atmosphere of said acylation chamber is heated so that the temperature of the gaseous atmosphere in contact with said scrolled hydroxylated material in said acylation chamber is at a temperature, known as the grafting temperature (Tg), below the vaporization temperature
Data Source
AI summary
The invention relates to a process for the acylation of a solid material, known as the hydroxylated material, bearing hydroxyl groups (—OH), known as reaction-generating hydroxyls, which are accessible and capable of reacting with at least one fatty acid chloride in gaseous form, said hydroxylated material being scrolled through a chamber, known as the acylation chamber, delimiting an internal space under a gaseous atmosphere. The invention also relates to an acylation device for performing said process.