High Silver Loaded Halide Removal Resins for Carbonylation Effluent
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Solution Overview
Problem
Current methods for removing halides, particularly iodides, from carbonylation reaction products are inefficient due to low silver loading in ion exchange resins, which leads to silver leaching and reduced iodide removal capacity, and require additional processing steps to manage corrosion metals, increasing costs and complexity.
Innovation Solution
A method using ion exchange resins loaded with 15 to 40 wt% silver(I) ions to treat carbonylation reaction mixtures, effectively reducing iodide concentrations from parts per million to parts per billion by contacting the resin with the reaction mixture under optimized conditions, thereby enhancing iodide removal efficiency and resin stability.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If low levels of silver loading (less than 12%) are used in ion exchange resins, then corrosion metals can be bound without displacing silver, but iodide removal capacity is insufficient
Solution Approach 1:
The patent changes the loading parameter of silver in the ion exchange resin from traditional low levels (less than 12%) to high levels (15-40 wt%). This parameter change resolves the contradiction by providing sufficient silver capacity for iodide removal while the resin's selective binding properties ensure corrosion metals do not displace the loaded silver, thus maintaining both high productivity and reliability
Solution Approach 2:
The high silver loaded ion exchange resin performs multiple functions simultaneously: it removes iodide through silver-halide binding and also binds corrosion metals through the resin's cation exchange capacity. This multi-functionality allows a single resin bed to handle both iodide removal and corrosion metal management, achieving high iodide removal capacity while maintaining resin stability through the selective binding mechanism
2Productivity
If high silver loading (15-40 wt%) is used in ion exchange resins, then iodide removal capacity increases, but silver leaching may increase
Solution Approach 1:
The patent employs a downstream reactor bed containing a trapping agent that captures leached silver ions. This approach accepts that some silver leaching will occur with high loading resins but prevents silver loss in the product stream by providing a sacrificial trapping bed that can be periodically regenerated or replaced, thus maintaining high iodide removal capacity while managing silver losses
Solution Approach 2:
The trapping agent in the downstream reactor bed acts as an intermediary that intercepts leached silver ions before they contaminate the product stream. This mediator captures the harmful silver ions through complexation or precipitation, allowing the high silver loading resin to function at full capacity without compromising product purity
3Productivity
If high silver loading is used, then open binding sites for corrosion metals are reduced, but iodide removal efficiency improves
Solution Approach 1:
The patent creates local quality differentiation in the resin bed by having regions with high silver loading optimized for iodide removal and relying on the resin's inherent cation exchange sites for corrosion metal binding. The selective binding affinity of silver for iodide ensures that even with reduced open sites, the resin maintains effectiveness by prioritizing iodide removal while corrosion metals bind to available cation exchange sites
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
The high silver loading in the ion exchange resins significantly reduces iodide concentrations in the product streams, improving the efficiency of halide removal and extending resin lifespan, while minimizing silver leaching and corrosion issues, thus enhancing the overall processing efficiency and cost-effectiveness.
Implementation Method 1
The cation, such as silver(I), binds the halide removing the halide from the effluent stream
Data Source
AI summary
The present disclosure relates to methods of removing halides from a reactor effluent comprising treating the halide containing carbonylation product with a resin or material comprising a metal ion with a metal loading of greater than 15 wt % are provided herein. In some aspects, the methods involve treating the halide containing carbonylation product with a silver loaded resin which comprises a loading of greater than 15 wt % of silver to remove inorganic or organic halides.