Integrated Reaction Distillation Tower for 1,3,5-Trioxane Preparation
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Solution Overview
Problem
The existing methods for preparing 1,3,5-trioxane are costly due to the need for separate distillation and extraction towers, leading to high formaldehyde concentration and frequent overhauls, and attempts to reduce this through water addition complicate the process and consume excessive energy.
Innovation Solution
A method using a reaction distillation tower with a reactor and integrated distillation and extraction units, where the water phase separated from the extraction unit is refluxed back into both units, maintaining formaldehyde concentration below 50 wt% to prevent para-formaldehyde precipitation and extend the overhaul cycle.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a distillation tower and an extraction tower are separately provided, then 1,3,5-trioxane can be prepared through distillation and extraction processes, but equipment investment costs and operating costs excessively increase
Solution Approach 1:
The patent combines the distillation tower and extraction tower into a single integrated reaction distillation tower. The distillation unit and extraction unit are merged into one apparatus, reducing the number of separate equipment pieces while maintaining both distillation and extraction functions. This directly addresses the cost issue by eliminating the need for two separate towers and their associated infrastructure.
Solution Approach 2:
The integrated reaction distillation tower performs multiple functions simultaneously: it conducts the cyclization reaction of formaldehyde, performs distillation to separate 1,3,5-trioxane-containing vapor, and carries out extraction using water-insoluble organic solvent. This multi-functional design eliminates the need for separate dedicated equipment for each process step.
2Device complexity
If a distillation unit and an extraction unit are integrally formed into one distillation apparatus, then equipment investment costs and operating costs are reduced, but the concentration of formaldehyde in the extraction unit becomes high, so para-formaldehyde periodically accumulates in the extraction unit
Solution Approach 1:
The patent extracts the harmful accumulation of para-formaldehyde from the system by introducing water into the extraction unit. The water reacts with or dilutes the concentrated formaldehyde, preventing para-formaldehyde precipitation and allowing the extraction process to continue normally without frequent overhauls.
Solution Approach 2:
Water acts as an intermediary substance introduced into the extraction unit to mediate the formaldehyde concentration issue. The water interacts with the high-concentration formaldehyde, preventing para-formaldehyde accumulation while allowing the extraction process to proceed. This intermediary substance resolves the contradiction between cost reduction and process reliability.
3Reliability
If water is externally supplied into the distillation system to prevent para-formaldehyde accumulation, then para-formaldehyde precipitation is prevented, but the process is complicated and energy is excessively consumed because water must be discharged to the outside of the distillation system
Solution Approach 1:
The system serves itself by utilizing the water already present in the reaction and distillation processes. Rather than requiring external water supply and subsequent energy-intensive discharge, the system uses its own internal water resources to prevent para-formaldehyde accumulation, eliminating the need for additional energy consumption.
Solution Approach 2:
The patent implements a feedback mechanism where water is introduced into the extraction unit based on the formaldehyde concentration levels. The system monitors and responds to the accumulating formaldehyde by introducing water to maintain proper concentration levels, creating a self-regulating system that prevents para-formaldehyde precipitation without excessive energy consumption.
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 reduces formaldehyde concentration, prevents para-formaldehyde precipitation, and extends the overhaul cycle while avoiding the energy-intensive water discharge required in previous methods.
Implementation Method 1
a water phase (a), which is separated from a stream discharged from the extraction unit (22) and then introduced into a decanter (30), is refluxed into the distillation unit (21) and the extraction unit (22)
Implementation Method 2
a stream discharged from the extraction unit (22) is introduced into a decanter (30) to be separated into an oil phase and a water phase
Data Source
AI summary
The present invention relates to a method for preparing 1,3,5-trioxane using a distillation tower including a reactor, a distillation section, and an extraction section. Particularly, the present invention relates to a method for preparing 1,3,5-trioxane, in which the water phase separated from the stream discharged through the extraction unit of the reaction distillation tower is used in the process of extracting 1,3,5-trioxane.