Nitration Process Impurity Removal via Secondary Nitrator

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Solution Overview

Problem

Industrial nitration processes face challenges in effectively removing non-aromatic impurities from the recovered and recycled excess aromatic reactant, leading to build-ups that can disrupt production and require costly purging, with existing methods like extractive distillation being complex and not cost-effective.

Innovation Solution

A method and apparatus that divert a portion of the recovered excess aromatic reactant for additional nitration, followed by processing to separate and remove non-aromatic impurities, utilizing a secondary nitrator and separation unit to enhance the volatility difference and facilitate easier separation.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Manufacturing precision

If extractive distillation is used to remove non-aromatic impurities, then separation effectiveness is improved, but device complexity and cost increase

Engineering Contradiction:

Improveseparation effectivenessVSAvoidprocess complexity

Core Design Contradiction:

Manufacturing precisionVSDevice complexity

Solution Approach 1:

The patent changes the chemical parameter of the mixture by nitrating non-aromatic impurities, transforming them into compounds with significantly different boiling points. This parameter change (chemical structure modification) enables effective separation through simple distillation, avoiding the need for complex extractive distillation processes while achieving the desired separation effectiveness

Inventive Principle:

Principle #35Parameter changes

Solution Approach 2:

The patent extracts the harmful non-aromatic impurities from the aromatic stream by selectively nitrating them. The nitrated impurities are then removed through distillation, effectively taking out the problematic components without requiring complex extraction equipment or solvents

Inventive Principle:

Principle #2Taking out (Extraction)

2Reliability

If periodic purging is used to remove non-aromatic impurities, then impurity build-up is controlled, but productivity and aromatic compound loss increase

Engineering Contradiction:

Improveproduction stabilityVSAvoidproduction efficiency

Core Design Contradiction:

ReliabilityVSProductivity

Solution Approach 1:

The patent converts the harmful non-aromatic impurities into beneficial nitrated products that can be easily separated. By nitrating the impurities in place, they transform from problematic components that require purging into separable compounds with different boiling points, eliminating the need for periodic purging and associated productivity losses

Inventive Principle:

Principle #22Blessing in disguise (Convert harm into benefit)

Solution Approach 2:

The nitration reaction acts as an intermediary process that transforms non-aromatic impurities into a different chemical form. This intermediate nitrated compound serves as a bridge, allowing easy separation through distillation while maintaining production continuity without periodic purging

Inventive Principle:

Principle #24Intermediary (Mediator)

3Productivity

If non-aromatic impurities are not removed, then productivity is maintained, but production reliability deteriorates due to impurity build-up

Engineering Contradiction:

Improveproduction continuityVSAvoidproduction stability

Core Design Contradiction:

ProductivityVSReliability

Solution Approach 1:

The patent applies preliminary nitration to non-aromatic impurities before they can accumulate to disruptive levels. By continuously nitrating impurities as they enter the system, the process prevents impurity build-up before it becomes a problem, maintaining both productivity and reliability simultaneously

Inventive Principle:

Principle #10Preliminary action

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 approach effectively controls the build-up of non-aromatic impurities by transforming them into nitrated products with significantly different boiling points, allowing for efficient removal and reducing the need for costly purging, while maintaining product quality.

Implementation Method 1

subjecting the formed stream to nitration to produce a stream comprising nitrated aromatic product and non-aromatic compounds

Methodology Applied

Scientific EffectNitration reaction: Chemical Bonding

Implementation Method 2

followed by processing to separate and remove non-aromatic impurities, utilizing a secondary nitrator and separation unit to enhance the volatility difference and facilitate easier separation

Methodology Applied

Scientific EffectDistillation: Distillation

Data Source

PatentUS9139509B2Removal of non-aromatic impurities from a nitration process

Publication Date: 2015.09.22 NORAM INT LTD

AI summary

A method and apparatus for removing non-aromatic impurities from non-nitrated aromatic reactant in a nitration production process, in which process an aromatic reactant is nitrated (100) to produce a nitrated aromatic product using a molar excess of the aromatic reactant, and non-nitrated aromatic reactant is recovered (102) from the produced nitrated aromatic product and is recycled (104) for use in the nitration production process. A portion of the removed excess non-nitrated aromatic reactant is diverted (106) and subjected to nitration (108). The nitrated stream may be further processed by separating out the spent acids (110) and the non-aromatic impurities (116). These streams may be sent (114, 118) to a suitable location in the nitration production train.