Sucralose-6-acetate Biphasic System Reduces DMF Decomposition
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Solution Overview
Problem
Existing methods for preparing sucralose-6-acetate result in excessive decomposition of DMF, leading to high production costs and environmental concerns due to the use of harmful solvents and byproducts like sulfur dioxide and chlorine hydride.
Innovation Solution
A biphasic liquid-liquid system is employed using an inert non-polar solvent, such as a high-boiling-point alkane, and N,N-dimethylformamide (DMF), where sucrose-6-acetate undergoes chlorination with phosgene or solid phosgene, followed by hydrolysis and crystallization to minimize DMF decomposition and enhance yield.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If DMF is used as solvent for chlorination of sucrose-6-acetate, then the reaction can proceed, but DMF decomposes excessively due to chlorine hydride production, increasing production cost
Solution Approach 1:
The patent extracts and removes the harmful byproduct chlorine hydride from the reaction system through a gas-liquid separator. This prevents chlorine hydride from attacking and decomposing DMF, thereby reducing DMF loss while maintaining reaction productivity. The separator continuously removes generated HCl gas, solving the contradiction between maintaining DMF as solvent and preventing its decomposition.
Solution Approach 2:
The gas-liquid separator acts as an intermediary device between the reaction system and the environment. It mediates the removal of chlorine hydride without interfering with the main chlorination reaction, allowing DMF to remain as solvent while protecting it from decomposition by the harmful byproduct.
2Productivity
If high temperature (90-98°C) is used to improve sucralose yield, then reaction efficiency increases, but DMF decomposition accelerates due to chlorine hydride production
Solution Approach 1:
The patent implements continuous removal of chlorine hydride through the gas-liquid separator during the entire reaction process. This continuous action allows the reaction to proceed at high temperature for extended periods without accumulating harmful byproducts, thereby maintaining both high productivity and low DMF decomposition.
Solution Approach 2:
The patent converts the harmful effect of chlorine hydride (which causes DMF decomposition) into a removable byproduct stream. By continuously separating and removing HCl gas, the system transforms a problematic side effect into a controlled output, allowing high-temperature reaction to proceed without excessive DMF loss.
3Productivity
If chlorinated ether is used as solvent, then sulfur dioxide and chlorine hydride depart quickly improving yield, but the solvent has higher toxicity, higher cost, and causes poor solubility of sucrose-6-acetate
Solution Approach 1:
The patent replaces the expensive and toxic chlorinated ether with DMF, which can be continuously regenerated. Instead of relying on a single-use expensive solvent, the system uses a cheaper solvent (DMF) that can be recovered and reused, reducing both cost and environmental impact while maintaining high yield through continuous byproduct removal.
Solution Approach 2:
The patent changes the solvent parameter from chlorinated ether to DMF, and compensates for the difference in byproduct removal capability by introducing the gas-liquid separator. This parameter change reduces solvent toxicity and cost while maintaining reaction efficiency through the added separation device.
4Productivity
If perfluorooctane is added as synergetic solvent, then reaction yield increases by 3%, but the solvent system becomes more complicated and requires sulfolane for DMF protection
Solution Approach 1:
The patent extracts the function of byproduct removal from the solvent system itself and places it in a dedicated gas-liquid separator device. This eliminates the need for complex solvent combinations like perfluorooctane and sulfolane, achieving the same protective effect through a simpler physical separation approach.
Solution Approach 2:
The gas-liquid separator serves as an intermediary that handles the byproduct removal function, allowing the solvent system to remain simple (just DMF) while still achieving high yield and low DMF decomposition. The separator mediates between the reaction mixture and the harmful byproducts without requiring complex solvent additives.
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 method significantly reduces DMF decomposition, achieves high reaction yields, and allows for the simple recycling of the non-polar solvent, thereby lowering production costs and environmental impact.
Implementation Method 1
a biphasic liquid-liquid system formed by an inert non-polar solvent and N,N-dimethylformamide (abbreviated as DMF)
Implementation Method 2
proceeding with cooling, settling the solution to form layers upon completion of the reaction
Implementation Method 3
sucrose-6-acetate and chlorinating agent engaging in chlorination reaction through heating
Implementation Method 4
engaging in chlorination reaction through heating
Implementation Method 5
proceeding with hydrolysis and neutralization of the DMF solution layer containing the product
Data Source
AI summary
The present invention discloses a method for preparing sucralose-6-acetate in a biphasic liquid-liquid system. The method comprises slowly dropwise adding an inert non-polar solvent containing a chlorinating agent to an N,N-dimethyl formamide (DMF) solution of sucrose-6-acetate; then reacting the biphasic liquid-liquid mixture at a certain temperature for 9-20 hours; cooling the system to room temperature after stopping heating, and settling the solution to form layers, an upper layer being an inert non-polar solvent layer, and a lower layer being a DMF solution layer containing the product; hydrolyzing, neutralizing, and filtering the lower layer to obtain a filtrate, and then concentrating the filtrate to obtain a concentrate; dissolving the concentrate in water, and obtaining the product by extraction using ethyl acetate and crystallization, the inert non-polar solvent being an alkane solvent containing 8-18 carbon atoms that is not mutually soluble with DMF. The method has a high product yield, and can significantly reduce the decomposition of DMF, thereby reducing costs.