Propylene Oxide Production via Controlled Epoxidation

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Solution Overview

Problem

Conventional methods for producing propylene oxide are inefficient in carrying out epoxidation reactions, result in significant loss of valuable components like propylene and propylene oxide, and require excessive energy for purification.

Innovation Solution

A method involving an epoxidation step with a titanium-containing silicon oxide catalyst, followed by propylene recovery and purification, where the organic peroxide concentration is controlled between 20 to 5,000 ppm to optimize reaction efficiency and minimize losses, using a combination of distillation and extraction techniques to recycle propylene and purify propylene oxide.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Productivity

If conventional methods are used for propylene oxide production, then the epoxidation reaction can be carried out, but the reaction efficiency is insufficient and valuable components are lost

Engineering Contradiction:

Improveepoxidation reaction efficiencyVSAvoidloss of propylene and propylene oxide

Core Design Contradiction:

ProductivityVSLoss of substance

Solution Approach 1:

The patent applies parameter changes by controlling the organic peroxide concentration within a specific range (20-5000 ppm) and managing the water content in the reaction solution. By adjusting these parameters, the epoxidation reaction efficiency is improved while minimizing the loss of valuable components like propylene and propylene oxide, directly resolving the technical contradiction between productivity and substance loss

Inventive Principle:

Principle #35Parameter changes

Solution Approach 2:

The patent implements feedback mechanisms by monitoring the concentration of organic peroxide and water in the reaction solution, and adjusting the reaction conditions accordingly. This feedback control ensures optimal reaction efficiency while preventing excessive loss of valuable components, addressing the contradiction between productivity and substance loss

Inventive Principle:

Principle #23Feedback

2Manufacturing precision

If conventional purification methods are used, then propylene oxide can be separated, but excessive energy is consumed

Engineering Contradiction:

Improvepropylene oxide purityVSAvoidenergy consumption for purification

Core Design Contradiction:

Manufacturing precisionVSUse of energy by moving object

Solution Approach 1:

The patent applies parameter changes by controlling the concentration of organic peroxide and water in the reaction solution to within specific ranges. This pre-control of parameters reduces the burden on subsequent purification steps, allowing propylene oxide to be separated with lower energy consumption while maintaining high purity, thus resolving the contradiction between manufacturing precision and energy use

Inventive Principle:

Principle #35Parameter changes

Solution Approach 2:

The patent implements preliminary action by controlling the reaction conditions (organic peroxide concentration and water content) during the epoxidation step to prevent formation of excessive impurities. This preliminary control simplifies the purification process and reduces energy consumption, addressing the contradiction between achieving high purity and the energy required for purification

Inventive Principle:

Principle #10Preliminary action

3Speed

If higher organic peroxide concentration is used, then reaction rate increases, but loss of valuable components increases

Engineering Contradiction:

Improvereaction rateVSAvoidloss of propylene and propylene oxide

Core Design Contradiction:

SpeedVSLoss of substance

Solution Approach 1:

The patent applies parameter changes by optimizing the organic peroxide concentration to within a specific range (20-5000 ppm) rather than using higher concentrations. This optimized parameter control maintains an adequate reaction rate while preventing excessive loss of valuable components, directly resolving the contradiction between reaction speed and substance loss

Inventive Principle:

Principle #35Parameter changes

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 efficiency of the epoxidation reaction, reduces losses of valuable components, and conserves energy required for purification by maintaining a controlled organic peroxide concentration within a narrower range, leading to a high-quality propylene oxide product.

Implementation Method 1

reacting an organic peroxide with propylene in the presence of a catalyst to obtain propylene oxide and an alcohol

Methodology Applied

Scientific EffectCatalysis: Catalysis

Implementation Method 2

distilling the propylene oxide obtained in the epoxidation step to obtain purified propylene oxide

Methodology Applied

Scientific EffectDistillation: Distillation

Data Source

PatentUS9102641B2Method for producing propylene oxide

Publication Date: 2015.08.11 SUMITOMO CHEM CO LTD

AI summary

A method for producing propylene oxide in which the concentration of an organic peroxide in a reaction solution after an epoxidation step is from 20 to 5,000 ppm by weight based on the amount excluding propylene in the reaction solution, the method comprising an epoxidation step of reacting an organic peroxide with propylene in the presence of a catalyst to obtain propylene oxide and an alcohol, a propylene recovery step of recovering the unreacted propylene in the epoxidation step and recycling the resulting propylene as a raw material of the epoxidation step, and a propylene oxide purification step of distilling the propylene oxide obtained in the epoxidation step to obtain purified propylene oxide.