Propylene Oxide Production via Cymene Concentration Control
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Solution Overview
Problem
The existing method for producing propylene oxide through recycling cumene is inefficient in terms of energy and reaction efficiency, particularly in the oxidation and epoxidation steps.
Innovation Solution
A method that includes an oxidation step where cumene reacts with an oxygen-containing gas to form cumene hydroperoxide, an epoxidation step where cumene hydroperoxide reacts with propylene in the presence of a catalyst to produce propylene oxide and cumyl alcohol, a separation step to isolate propylene oxide, a cumene conversion step to regenerate cumene, and a cumene recovery step that maintains a controlled cymene concentration through distillation, optimizing the process for improved efficiency.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If cumene is recycled to the oxidation step, then material utilization is improved, but the oxidation reaction rate and conversion ratio are insufficient
Solution Approach 1:
The patent changes the concentration parameter of cymene in the recovery mixture to 100-5000 ppm by weight, which optimizes the oxidation reaction rate and conversion ratio. This parameter adjustment allows cumene to be recycled more effectively while maintaining high reaction efficiency in the oxidation step.
Solution Approach 2:
The patent implements a feedback mechanism by controlling the cymene concentration in the recovery mixture through distillation. The cymene concentration is monitored and adjusted to maintain steady-state levels, which ensures optimal reaction conditions are maintained throughout the recycling process.
2Productivity
If distillation is performed to control cymene concentration, then production efficiency is improved, but energy consumption increases
Solution Approach 1:
The patent optimizes the distillation process by controlling the cymene concentration within a specific range (100-5000 ppm). This parameter control allows for effective separation with reduced energy consumption, as the distillation can be performed under milder conditions compared to achieving complete separation.
Solution Approach 2:
The patent applies partial action by removing only the excess cymene beyond the optimal concentration range rather than achieving complete removal. This partial separation approach achieves sufficient production efficiency while minimizing energy consumption associated with full distillation.
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 method enhances the oxidation reaction rate and conversion ratio of cumene hydroperoxide, leading to more efficient production of propylene oxide by controlling cymene concentration and optimizing the recycling of cumene.
Implementation Method 1
contacting a mixture containing cumene and cymene with an oxygen-containing gas to cause a reaction between cumene in the mixture and oxygen in the gas
Implementation Method 2
contacting the reaction mixture containing cumene hydroperoxide obtained in the oxidation step with propylene in the presence of a catalyst to cause a reaction between cumene hydroperoxide in the reaction mixture and propylene
Implementation Method 3
distilling the reaction mixture containing cumene obtained in the cumene conversion step, wherein the distillation is performed under a condition for removing 0.025 wt% or more of cymene contained in the reaction mixture containing cumene
Data Source
AI summary
Provided is a method for more efficiently producing propylene oxide, specifically, a method for producing propylene oxide comprising: 1) oxidation step, 2) epoxidation step, 3) separation step, 4) cumene conversion step, and 5) cumene recovery step, wherein at least a part of a mixture containing cumene and cymene to be supplied to the oxidation step is a recovery mixture containing cumene and cymene obtained in the cumene recovery step. The cumene recovery step is a step of obtaining a recovery mixture containing cumene and cymene with a cymene concentration of 100 ppm by weight or more and less than 10000 ppm by weight (the cymene concentration is calculated based on the weight of the recovery mixture containing cumene and cymene obtained in the cumene recovery step) by distilling the reaction mixture containing cumene obtained in the cumene conversion step.