Solid Acid Catalyst for Cyclohexanone Dimer Production
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Solution Overview
Problem
Current methods for producing cyclohexanone dimers face issues such as low selectivity, high production costs, environmental pollution, and corrosion due to the use of acid or base catalysts, along with the need for water-removing agents that increase costs and complexity.
Innovation Solution
A method utilizing a solid acid catalyst comprising tungsten metal oxide and a carrier with Lewis and Brønsted acid sites, such as zeolite, for cyclohexanone condensation at controlled temperatures, eliminating the need for water-removing agents and simplifying purification processes.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If organic acid or inorganic acid catalyst is used for cyclohexanone condensation, then the reaction can proceed, but severe corrosion to production apparatus occurs and complex purification process is required
Solution Approach 1:
The patent changes the physical state parameter of the acid catalyst from liquid (organic or inorganic acid) to solid (solid acid catalyst), which maintains catalytic activity while eliminating corrosion issues and simplifying purification processes
Solution Approach 2:
The solid acid catalyst can be easily separated from the reaction mixture through filtration and regenerated for repeated use, replacing the need for complex purification processes required when using liquid acid catalysts
2Productivity
If organic acid or inorganic acid catalyst is used for cyclohexanone condensation, then the reaction can proceed, but complex purification process is required as catalyst remains in product
Solution Approach 1:
The patent changes the physical state parameter of the acid catalyst from liquid to solid, enabling simple filtration-based separation and eliminating complex purification processes
Solution Approach 2:
The solid acid catalyst is easily extracted from the reaction mixture through filtration, removing the catalyst from the product stream and simplifying the purification process
3Productivity
If base catalyst such as calcium hydroxide is used for cyclohexanone condensation, then the reaction can proceed, but poor reaction effects after catalyst regeneration occur
Solution Approach 1:
The patent changes from base catalyst to solid acid catalyst, which can be easily regenerated by simple calcination to remove carbon deposits, restoring catalytic activity for repeated use
Solution Approach 2:
The solid acid catalyst can be recovered from the reaction mixture through filtration and regenerated by calcination, allowing repeated use and maintaining consistent reaction performance
4Manufacturing precision
If water-removing agent such as cyclohexane or n-heptane is used to remove water from reaction, then byproduct formation is avoided, but distillation apparatus is required at later stage increasing production cost
Solution Approach 1:
The patent removes the water-removing agent from the process entirely by using a solid acid catalyst that enables the reaction to proceed without requiring water removal, eliminating the need for distillation apparatus
Solution Approach 2:
The patent changes the reaction conditions by using a solid acid catalyst that allows the condensation reaction to proceed efficiently without requiring water removal, changing the process from one needing water removal to one that doesn't
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
Enhances reaction rate and selectivity while reducing byproduct formation and production costs, offering a more efficient and cost-effective process for cyclohexanone dimer production.
Implementation Method 1
performing condensation of cyclohexanone in the presence of a solid acid catalyst to produce a cyclohexanone dimer, wherein the solid acid catalyst comprises metal oxide of tungsten and a carrier with Lewis acid sites and Brønsted acid sites
Implementation Method 2
a carrier with Lewis acid sites and Brønsted acid sites
Implementation Method 3
a carrier with Lewis acid sites and Brønsted acid sites
Data Source
AI summary
A method for producing a cyclohexanone dimer is provided. The method includes the steps of performing condensation of cyclohexanone in the presence of a solid acid catalyst to obtain the cyclohexanone dimer, wherein the solid acid catalyst includes metal oxide of tungsten and a carrier with Lewis acid sites and Brønsted acid sites. The method of the present disclosure has an advantage of mild reaction condition, fast reaction rate and high selectivity, thereby realizing the value of the industrial application.