Parallel Oxidation Reactors Stabilize Product Purity

Resolve Bottlenecks,
Find Innovative SolutionsGenerate Solutions

Solution Overview

Problem

Heterogeneously catalyzed gas phase partial oxidation processes for organic precursor compounds face challenges in maintaining target product selectivity and purity due to synchronous changes in target and by-product selectivity over catalyst operating time, leading to complex and economically burdensome removal line configurations.

Innovation Solution

Operating two oxidation reactor systems in parallel, where one catalyst charge has undergone longer partial oxidation than the other, allows for mixing of product streams to form a mixture stream before removal, thereby maintaining target product purity and extending catalyst life without additional costs.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Manufacturing precision

If multiple catalyst charges are operated in parallel with different operating times, then target product selectivity and purity are stabilized, but device complexity increases

Engineering Contradiction:

Improvetarget product purityVSAvoidremoval line configuration

Core Design Contradiction:

Manufacturing precisionVSDevice complexity

Solution Approach 1:

The catalyst system is segmented into multiple parallel charges with different operating times. This segmentation allows some catalysts to be in decline phase while others are still active, enabling the mixture to maintain stable selectivity and purity without requiring complex removal line configurations.

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

Product streams from multiple catalyst charges with different operating histories are merged into a single mixture stream before removal. This merging approach stabilizes target product purity by compensating for variations in individual catalyst performances, thereby simplifying the removal line design.

Inventive Principle:

Principle #5Merging (Combining)

2Productivity

If catalyst charges are operated until synchronous selectivity changes occur, then production capacity is maximized, but removal process complexity increases

Engineering Contradiction:

Improveproduction capacityVSAvoidremoval line configuration

Core Design Contradiction:

ProductivityVSDevice complexity

Solution Approach 1:

Catalyst charges are operated at different times and replaced at different stages to create a deliberate distribution of operating histories. This preliminary action ensures that when products are removed, the mixture of catalyst ages provides stable selectivity, avoiding the need for complex removal line configurations.

Inventive Principle:

Principle #10Preliminary action

Solution Approach 2:

The operating parameters of catalyst charges are varied in terms of operating time and replacement timing. By controlling these parameters, the system maintains high production capacity while ensuring that the mixture of catalysts produces stable target product selectivity, thereby simplifying the removal process.

Inventive Principle:

Principle #35Parameter changes

3Duration of action of stationary object

If all catalyst charges are replaced simultaneously, then catalyst life is extended, but production continuity is disrupted

Engineering Contradiction:

Improvecatalyst lifeVSAvoidproduction continuity

Core Design Contradiction:

Duration of action of stationary objectVSProductivity

Solution Approach 1:

Catalyst charges are segmented into multiple groups with different replacement schedules. This allows continuous production by having some catalysts replaced while others continue operating, extending overall catalyst life without disrupting production continuity.

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

The catalyst system is designed to maintain continuous useful action through staggered replacements. By operating and replacing catalysts at different times, the system ensures continuous production while extending the overall catalyst life cycle, avoiding production interruptions.

Inventive Principle:

Principle #20Continuity of useful 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 simplifies the removal process by stabilizing target product selectivity and purity, reducing economic burdens by prolonging catalyst life and simplifying the removal line configuration.

Implementation Method 1

heterogeneously catalyzed gas phase partial oxidation of at least one organic precursor compound with molecular oxygen

Methodology Applied

Scientific EffectHeterogeneous catalysis: Catalysis

Implementation Method 2

partial oxidation of at least one organic precursor compound with molecular oxygen in the gas phase

Methodology Applied

Scientific EffectPartial oxidation: Oxidation

Implementation Method 3

mixing together at least two of the at least two product gas streams... to form a mixture stream

Methodology Applied

Scientific EffectGas mixing:

Implementation Method 4

subsequent removal of the at least one target compound from the at least two product gas streams

Methodology Applied

Scientific EffectGas separation:

Data Source

PatentUS8394345B2Process for preparing at least one organic target compound by heterogeneously catalyzed gas phase partial oxidation

Publication Date: 2013.03.12 BASF SE

AI summary

A process for preparing an organic target compound by heterogeneously catalyzed gas phase partial oxidation of an organic precursor compound with molecular oxygen in two oxidation reactor lines operated in parallel and removal of the target compound from the mixture of the product gas streams in a workup line, wherein the catalysts charge of one of the oxidation lines comprises a portion of catalyst over which the heterogeneously catalyzed gas phase partial oxidation has already been carried out for longer than over the portions of catalyst of the catalyst charge of the other oxidation reactor line.