Reactive Chromatography Unit for Equilibrium-Limited Acylation
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Solution Overview
Problem
Acylation reactions and similar equilibrium-limited reactions face challenges in achieving high conversion levels due to chemical equilibrium limitations, often requiring distillation to remove products, which can be complicated by the formation of azeotropic mixtures that are difficult to separate.
Innovation Solution
The process utilizes a reactive chromatography unit (RCU) to conduct and separate the equilibrium-limited reaction between a first organic donor reactant and a second organic acceptor reactant, avoiding the formation of water as a reaction product, thereby preventing the formation of aqueous azeotropes, and allowing for higher conversion levels by separating and recycling reaction products.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If reactive distillation is used to remove products and drive conversion beyond equilibrium, then conversion level is improved, but the process becomes complicated by formation of azeotropic mixtures that are difficult to separate
Solution Approach 1:
The patent extracts the product separation function from the reaction system by using a reactive extraction column where the organic phase and aqueous phase separate automatically based on density differences. The co-product (alcohol) is extracted into the aqueous phase while the desired product remains in the organic phase, eliminating the need for complex distillation of azeotropic mixtures and enabling conversion beyond equilibrium limits.
Solution Approach 2:
The patent introduces an aqueous base solution as an intermediary extraction medium that selectively dissolves the co-product (alcohol) from the reaction mixture. This intermediary phase facilitates continuous removal of the co-product without requiring direct distillation of the organic reactants and products, thereby avoiding azeotrope formation complications.
2Loss of substance
If distillation is used to separate reaction products, then product removal is achieved, but additional unit operations and equipment are required
Solution Approach 1:
The patent merges the chemical reaction and product separation operations into a single reactive extraction column. The reaction occurs in the organic phase while simultaneous liquid-liquid extraction removes the co-product into the aqueous phase. This combination eliminates the need for separate reaction vessels and distillation columns, reducing the number of unit operations and equipment required.
Solution Approach 2:
The reactive extraction column performs multiple functions simultaneously: it serves as both the reaction vessel for the acylation reaction and the separation device for removing the co-product. The column accommodates both organic and aqueous phases, enabling reaction and extraction to occur in the same equipment, thereby eliminating additional unit operations.
3Ease of operation
If equilibrium-limited reaction is conducted without product removal, then process is simple, but conversion is limited by chemical equilibrium
Solution Approach 1:
The patent implements continuous removal of the co-product from the reaction zone through the aqueous extraction phase. As the co-product is continuously extracted into the aqueous phase and removed from the system, the reaction equilibrium is continuously shifted toward product formation. This continuous action maintains high conversion levels without requiring complex batch processing or intermittent distillation operations.
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 achieves conversion levels greater than the equilibrium conversion value, simplifying the process by avoiding the separation difficulties associated with azeotropic mixtures and enabling high overall conversion of the reactants without the need for additional unit operations.
Implementation Method 1
The RCU has separation media to separate a product mixture of the FAP and the SDCP. The product mixture is separated into a raffinate that includes the FAP and an extract that contains the SDCP.
Implementation Method 2
The process utilizes a reactive chromatography unit (RCU) to conduct and separate the equilibrium-limited reaction
Implementation Method 3
The RCU has separation media to separate a product mixture of the FAP and the SDCP
Data Source
AI summary
The present disclosure provides for a process for an equilibrium limited reaction using reactive chromatography unit (RCU) in which a first organic donor reactant (FODR) and a second organic acceptor reactant (SOAR) react to form a product mixture of a first acceptor product (FAP) and a second donor co-product (SDCP). The equilibrium-limited reaction does not produce water. The RCU has separation media to separate the product mixture into a raffinate and an extract. The FODR is in a stoichiometric deficit relative to the SOAR for the equilibrium limited reaction, so that the SOAR acts as the eluent for both the raffinate and the extract, and so as not to produce an azeotrope of FODR and the SDCP in the extract.