One-Pot Propionic Acid Process Without Hydrogen Oxidation
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Solution Overview
Problem
The traditional production of propionic acid from ethylene is costly due to the use of expensive hydrogen gas and results in unwanted byproducts like acetic acid during oxidation.
Innovation Solution
A one-pot alkoxycarbonylation/hydrolysis process using a catalyst system comprising a Group 8 to 10 transition metal compound and an activating anion, with a phosphorous compound for palladium, to convert ethylene into propionic acid at elevated temperature and pressure.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Quantity of substance
If the traditional hydroformylation process is used to produce propionic acid from ethylene, then propionic acid can be produced, but the process becomes costly due to the use of expensive hydrogen gas
Solution Approach 1:
The patent extracts and eliminates the need for expensive hydrogen gas from the traditional hydroformylation process by replacing it with water as the hydrogen source in alkoxycarbonylation, thereby reducing production costs while maintaining propionic acid output
Solution Approach 2:
The patent changes the chemical parameters of the reaction process by substituting hydrogen gas with water and using different catalyst systems (Group 8-10 transition metals with activating anions), transforming the reaction pathway from hydroformylation to alkoxycarbonylation to achieve lower cost production
2Quantity of substance
If air oxidation is used to convert propionaldehyde to propionic acid, then propionic acid production continues, but unwanted byproducts like acetic acid are generated
Solution Approach 1:
The patent removes the oxidation step entirely from the process pathway, extracting the harmful byproduct formation issue by replacing oxidation with alkoxycarbonylation followed by hydrolysis, which selectively produces propionic acid without generating acetic acid or other unwanted byproducts
Solution Approach 2:
The patent introduces an intermediary alkoxycarbonylation reaction that converts ethylene to alkyl carbonate intermediates, which then hydrolyze to propionic acid, avoiding the direct oxidation pathway that generates harmful byproducts
3Quantity of substance
If a multi-step process is used for propionic acid production, then each reaction can be optimized, but the process complexity increases with multiple reaction vessels and steps
Solution Approach 1:
The patent merges the alkoxycarbonylation and hydrolysis steps into a single integrated process that occurs in one reaction vessel, combining multiple functions into a unified system that reduces device complexity while maintaining efficient propionic acid production
Solution Approach 2:
The catalyst system exhibits multi-functionality by facilitating both alkoxycarbonylation and subsequent hydrolysis reactions within the same reaction environment, allowing a single reaction vessel to perform multiple transformation steps
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
Facilitates the efficient and continuous production of propionic acid with reduced byproduct formation, utilizing a homogeneous catalyst system in a single reaction vessel.
Implementation Method 1
treating ethylene with a C1-C6 alkanol, water, and carbon monoxide in the presence of a catalyst system comprising the reaction product of (a) a Group 8 to 10 transition metal compound such as a palladium or ruthenium compound; and (b) an activating anion
Implementation Method 2
hydrolysis to provide propionic acid
Data Source
AI summary
Provided is a one-pot process for preparing propionic acid, which comprises (i) treating ethylene with a C1-C6 alkanol, water, and carbon monoxide in the presence of a catalyst system comprising the reaction product of (a) a Group 8 to 10 transition metal compound such as a palladium or ruthenium compound; and (b) an activating anion, at elevated temperature and pressure. The process also provides a facile, continuous process for the preparation of propionic acid via the alkoxycarbonylation of ethylene at elevated temperature and pressure followed by hydrolysis, in one reaction vessel.