Nitrate Ester Production With Phase-Transfer Catalysis
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Solution Overview
Problem
Conventional methods for producing nitrate esters, such as glycidol nitrate, are hazardous, expensive, and generate significant waste due to the use of corrosive reagents and acidic conditions, making large-scale production dangerous and costly.
Innovation Solution
A method involving the reaction of an alcohol compound with an electrophilic compound to form a sulfonate, followed by reaction with a nitrate containing compound in the presence of a phase transfer catalyst, or reacting a halogenated compound with a nitrate containing compound, to produce nitrate esters in microfluidic or plug flow reactors, avoiding acidic conditions and using safer, less expensive reagents.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If conventional nitration methods using mixed acids are used, then nitrate esters can be produced, but the process becomes hazardous and generates significant waste due to corrosive reagents
Solution Approach 1:
The patent introduces a phase transfer catalyst as an intermediary substance that enables the reaction between nitrate esters and substrates without requiring corrosive mixed acids. The catalyst facilitates electron transfer and reaction progression while maintaining a safer, non-corrosive reaction environment, thus eliminating the harmful acidic conditions while preserving manufacturing capability
Solution Approach 2:
The invention fundamentally changes the chemical parameters of the nitration process by replacing traditional acid-based reagents with alternative reagent systems that operate under different chemical mechanisms. This parameter change transforms the process from highly corrosive to safer conditions while maintaining productivity
2Productivity
If large excess of corrosive reagents are used in batch processes, then nitrate ester production is achieved, but processing equipment becomes damaged and waste remediation costs increase
Solution Approach 1:
The patent extracts and removes the harmful corrosive reagents from the process system entirely. By eliminating the need for large excesses of mixed acids, the method prevents equipment degradation and waste generation while maintaining productive nitrate ester synthesis through alternative reagent systems
Solution Approach 2:
The invention eliminates the need to manage and remediate hazardous waste streams by using reagents that do not generate corrosive byproducts. The process achieves productivity without creating waste that requires intensive remediation, effectively discarding the harmful waste management step from the process
3Ease of manufacture
If traditional batch processes are used for GLYN production, then production is achieved, but capital cost is high and scaling up is difficult due to hazardous conditions
Solution Approach 1:
The patent segments the nitration process into discrete, controllable steps using phase transfer catalysis, making each step safer and more manageable. This segmentation enables simplified process design that reduces capital requirements while maintaining scalability, as each segmented step can be independently optimized and controlled
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 method produces nitrate esters efficiently and safely, with high purity and stability, enabling scalable production without hazardous intermediates and reducing waste, and is suitable for producing glycidol nitrate and other nitrate esters.
Implementation Method 1
combining a solution comprising glycidol sulfonate and an organic solvent with an aqueous solution comprising a metal nitrate compound and a phase transfer catalyst to form an emulsion
Implementation Method 2
combining a solution comprising glycidol sulfonate and an organic solvent with an aqueous solution comprising a metal nitrate compound and a phase transfer catalyst to form an emulsion
Data Source
AI summary
A method of producing a nitrate ester is disclosed and comprises reacting an alcohol compound and an electrophilic compound to form a sulfonate compound. The sulfonate compound is reacted with a nitrate containing compound to form the nitrate ester. Additional methods of producing glycidyl nitrate or a nitrate ester are also disclosed.