Reactive Distillation Tower for Alkylphenol Production

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Solution Overview

Problem

Current methods for producing alkylphenol, such as traditional fixed-bed reactors and reactive distillation, face challenges with high energy consumption and catalyst deactivation due to byproduct generation, requiring excessive phenol charging and inefficient energy use.

Innovation Solution

A method involving a reactive distillation tower where phenol is charged above the olefinic compound, with a lower boiling point, allowing for a reduced molar ratio and increased conversion of olefinic compounds to alkylphenol, utilizing a solid catalyst like ion-exchange resin, and optimizing the reaction conditions to minimize energy consumption.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Temperature

If traditional fixed-bed reactor or stirring reactor is used for alkylation reaction, then the reaction can be carried out, but the temperature becomes high due to exothermic reaction requiring heat energy removal and catalyst pores get blocked by byproducts decreasing catalytic activity

Engineering Contradiction:

Improvereaction temperatureVSAvoidheat energy removal requirement

Core Design Contradiction:

TemperatureVSLoss of energy

Solution Approach 1:

The patent combines the reaction zone and distillation zone into a single reactive distillation tower, merging the alkylation reaction with separation operations. This integration allows the exothermic reaction to occur while simultaneously removing byproducts through distillation, preventing catalyst pore blockage and reducing energy consumption for heat removal.

Inventive Principle:

Principle #5Merging (Combining)

Solution Approach 2:

The patent extracts byproducts from the reaction mixture through distillation in the same tower where the reaction occurs. By continuously removing byproducts via the distillation zone, the system prevents catalyst deactivation and maintains optimal reaction conditions without requiring separate heat removal systems.

Inventive Principle:

Principle #2Taking out (Extraction)

2Object-generated harmful factors

If excessive amount of phenol is charged into reactor to reduce byproduct generation, then byproduct generation is reduced, but energy consumption for recycling phenol is increased

Engineering Contradiction:

Improvebyproduct generationVSAvoidenergy consumption for phenol recycling

Core Design Contradiction:

Object-generated harmful factorsVSUse of energy by moving object

Solution Approach 1:

The patent implements a feedback mechanism where the distillation zone continuously separates and removes byproducts from the reaction zone. This feedback loop maintains high phenol conversion by preventing byproduct accumulation, eliminating the need for excessive phenol charging and subsequent recycling operations.

Inventive Principle:

Principle #23Feedback

Solution Approach 2:

The patent ensures continuous useful action by maintaining steady-state operation where reactants continuously flow through the reaction zone and products are continuously removed via distillation. This continuous operation achieves high conversion without requiring phenol recycling, optimizing energy efficiency.

Inventive Principle:

Principle #20Continuity of useful action

3Productivity

If reactive distillation is used to produce alkylated aromatic compound, then the process can be continuous, but high molar ratio of aromatic hydrocarbon to olefine is still required

Engineering Contradiction:

Improvecontinuous production capabilityVSAvoidmolar ratio of phenol to olefinic compound

Core Design Contradiction:

ProductivityVSQuantity of substance

Solution Approach 1:

The patent applies local quality by creating distinct functional zones within the reactive distillation tower: a reaction zone with specific catalyst properties for alkylation and a distillation zone with different physical properties for separation. This zonation allows optimized local conditions for both reaction and separation, achieving high conversion without excessive phenol charging.

Inventive Principle:

Principle #3Local quality

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 a high conversion rate of 99.9% for olefinic compounds, reducing the need for phenol recycling and subsequent energy consumption while maintaining a high yield of alkylphenol, thus simplifying the process and saving energy.

Implementation Method 1

reactive distillation is also employed to produce an alkylated aromatic compound

Methodology Applied

Scientific EffectDistillation: Distillation

Implementation Method 2

the boiling point of the olefinic compound is lower than that of the phenol

Methodology Applied

Scientific EffectBoiling point difference: Boiling

Implementation Method 3

utilizing a solid catalyst like ion-exchange resin

Methodology Applied

Scientific EffectCatalysis: Catalysis

Implementation Method 4

the temperature is high due to the exothermic reaction; therefore, heat energy needs to be removed from the reactor

Methodology Applied

Scientific EffectHeat transfer: Conduction (thermal)

Data Source

PatentUS9556093B2Method for producing alkylphenol

Publication Date: 2017.01.31 CHANG CHUN PETROCHEMICAL CO LTD

AI summary

A method for producing alkylphenol is provided. The method includes charging phenol and an olefinic compound into a reaction zone of a reactive distillation tower for a reaction; and separating a product stream containing alkylphenol from the reactive distillation tower, wherein the boiling point of the olefinic compound is lower than that of the phenol, and the phenol is charged into the reactive distillation tower at a charging position located above a position for charging the olefinic compound.