Resin Catalyst Process for Alkyl Nitrite Selectivity
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Solution Overview
Problem
The existing processes for producing C1-C4 alkyl nitrite in the CO coupling method suffer from low selectivity and significant side reactions, particularly the formation of nitric acid, leading to increased energy consumption and apparatus erosion.
Innovation Solution
A process involving a resin catalyst and/or a porous filler layer in a rotating high-gravity reactor, where nitrogen oxide, oxygen, and C1-C4 alkanol are reacted under controlled conditions, including specific temperature, pressure, and molar ratios, to enhance selectivity and inhibit side reactions.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Loss of energy
If the gaseous phase method is used for CO coupling to produce oxalate, then the production cost and energy consumption are reduced compared to liquid phase method, but side reactions occur leading to formation of nitric acid which increases energy consumption and erodes apparatus
Solution Approach 1:
The patent changes the reaction parameters by introducing a resin catalyst and controlling the molar ratio of reactants (NO:O2:ROH = 1:(0.5-2): (1-10)) to suppress nitric acid formation while maintaining high energy efficiency. The resin catalyst modifies the reaction pathway to favor alkyl nitrite production over nitric acid formation.
Solution Approach 2:
The resin catalyst acts as an intermediary substance that facilitates the desired reaction between CO and ROH to form alkyl nitrite while preventing the side reaction that produces nitric acid. The catalyst selectively promotes the formation of the desired product and inhibits harmful byproducts.
2Productivity
If conventional CO coupling process is used, then the process is simple, but selectivity of alkyl nitrite is low and side reactions are significant
Solution Approach 1:
The patent improves selectivity by changing key process parameters: introducing a resin catalyst, controlling temperature (0-150°C), pressure (-0.09-1.5 MPa), and molar ratios of reactants. These parameter changes enable high selectivity (>99%) while maintaining reasonable process complexity.
Solution Approach 2:
The resin catalyst provides local catalytic activity with specific selectivity for alkyl nitrite formation. The catalyst creates localized active sites that favor the desired reaction pathway, improving product selectivity without requiring complex process modifications throughout the entire system.
3Productivity
If high pressure conditions are used in liquid phase CO coupling, then the reaction efficiency is improved, but apparatus corrosion increases and catalyst loses during reaction
Solution Approach 1:
The patent changes the pressure parameter range (-0.09-1.5 MPa) and introduces a resin catalyst that enables efficient reactions at lower pressures compared to conventional liquid phase methods. This reduces apparatus corrosion while maintaining high reaction efficiency and catalyst stability.
Solution Approach 2:
The patent replaces the liquid phase mechanical system with a gaseous phase system using a resin catalyst. This substitution eliminates the corrosion problems associated with liquid phase reactions while maintaining reaction efficiency through catalytic action and controlled gas-phase chemistry.
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 selectivity of C1-C4 alkyl nitrite greater than 99% by improving gas-liquid mass transfer and reducing the formation of side products like nitric acid, thereby increasing the efficiency and reducing raw material consumption.
Implementation Method 1
loading a resin catalyst layer and/or a porous filler layer into a reactor
Implementation Method 2
improving gas-liquid mass transfer
Implementation Method 3
rotating high-gravity reactor
Implementation Method 4
reacting under the conditions including a reaction temperature of from 0 to 150° C., a reaction pressure of from −0.09 to 1.5 MPa
Data Source
AI summary
The present invention relates to a process for producing C1-C4 alkyl nitrite, comprising loading a resin catalyst layer and/or a porous filler layer into a reactor, passing nitrogen oxide, oxygen and C1-C4 alkanol as raw materials through the resin catalyst layer and/or porous filler layer in a counter current, parallel current or cross current manner, reacting under the conditions including a reaction temperature of from 0 to 150° C., a reaction pressure of from −0.09 to 1.5 MPa, a molar ratio of C1-C4 alkanol/nitrogen oxide of 1-100:1, a molar ratio of nitrogen oxide/oxygen of 4-50:1, to obtain an effluent containing C1-C4 alkyl nitrite, wherein said nitrogen oxide is NO, or a mixed gas containing NO and one or more selected from N2O3 and NO2.