Purifying (Meth)acrylic Esters with Divided Wall Column
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Solution Overview
Problem
The existing processes for producing C1-C4 (meth)acrylic esters through direct esterification face challenges in achieving high purity due to the formation of impurities and the complexity and energy cost of multi-step distillation and separation methods, particularly with the presence of water, which complicates the use of divided wall columns.
Innovation Solution
A process utilizing a divided wall column combined with a decanter for purification, where a single polymerization inhibitor is used at the top condenser to stabilize the ester, allowing for efficient separation and stabilization of C1-C4 (meth)acrylic esters, reducing heat exposure and energy consumption, and enabling the production of high-purity esters with simplified stabilization and lower costs.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If conventional two-column distillation is used to purify (meth)acrylic esters, then high purity is achieved, but energy consumption increases and thermal degradation occurs
Solution Approach 1:
The patent combines two separate distillation columns into a single divided wall column (DWC) with internal partitioning. The DWC integrates the rectification and stripping sections within one vessel, reducing the number of heating zones and condensers required. This merging maintains the separation efficiency of two columns while significantly reducing energy consumption by eliminating redundant heating and cooling cycles.
Solution Approach 2:
The divided wall column is segmented into distinct rectification and stripping sections by an internal partition wall. This segmentation allows independent optimization of each section's operating conditions, enabling efficient separation of light compounds, ester, and heavy by-products simultaneously within a single column, thereby reducing thermal exposure time and energy requirements.
2Manufacturing precision
If conventional two-column distillation is used, then heavy by-products are removed, but thermal degradation increases forming more heavy by-products
Solution Approach 1:
The divided wall column performs preliminary separation of light compounds in the rectification section before the crude mixture enters the stripping section. This preliminary action prevents light compounds from being exposed to high temperatures in the stripper, reducing thermal degradation. The internal partition ensures that only the necessary portion of the mixture undergoes intensive heating for heavy by-product removal.
Solution Approach 2:
The divided wall column design allows the purification process to rush through the separation stages more quickly by enabling simultaneous operation of rectification and stripping sections. The optimized flow paths and internal geometry reduce residence time at high temperatures, minimizing thermal degradation while maintaining effective separation of impurities.
3Stability of the object's composition
If multiple polymerization inhibitors are used in conventional processes, then stabilization is achieved, but process complexity and cost increase
Solution Approach 1:
The patent employs a single polymerization inhibitor that performs multiple stabilization functions throughout the entire purification process. The inhibitor is introduced at the top of the divided wall column and remains effective through both the rectification and stripping sections, as well as in the final ester product. This universal inhibitor replaces the conventional requirement for multiple different inhibitors, simplifying the stabilization process while maintaining comprehensive protection against polymerization.
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 results in high-purity C1-C4 (meth)acrylic esters with reduced heat degradation and energy costs, achieving purity equivalent to conventional facilities while minimizing the use of expensive polymerization inhibitors and simplifying the stabilization process.
Implementation Method 1
the crude reaction mixture is subjected to a distillation in a first column, termed topping column
Implementation Method 2
the condensed stream is subjected to a decanter, making it possible to separate an organic phase and an aqueous phase
Data Source
AI summary
The subject of the invention is a process for recovering/purifying a C1-C4 (meth)acrylic ester from a crude reaction mixture comprising said ester, the process being carried out using a purification system comprising a divided wall column and a decanter, resulting in a simplification of the process and in a high productivity of the ester produced corresponding to the standards in terms of purity. The invention also relates to a process for producing C1-C4 (meth)acrylic ester comprising this recovery/purification process.