TCE Dimerization Route for Scalable Chlorofluorobutane Production
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Solution Overview
Problem
Existing methods for producing chlorofluorobutane (CFB) are inefficient and lack a scalable process for utilizing by-products like trichloroethylene (TCE), which is environmentally problematic, and there is a need for a method to produce chlorinated and fluorinated butane or butadiene derivatives for low environmental impact etching gases.
Innovation Solution
A method involving dimerization, chlorination, dehydrochlorination, fluorination, and dechlorination reactions at controlled temperatures and pressures to convert TCE into chlorinated and fluorinated butane or butadiene derivatives, using free radical generating agents, Lewis acid catalysts, and fluorinating agents like ClF3 and ClF.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If TCE is dimerized using conventional small-scale methods, then chlorinated butylene or chlorinated butadiene can be formed, but the production scale is limited and cannot be expanded for mass production
Solution Approach 1:
The patent changes the reaction parameters by using a dimer of TCE as solvent instead of conventional solvents, and conducting the reaction at elevated temperatures (100-200°C) to achieve both high productivity and scalability. This parameter change enables mass production while maintaining ease of manufacture
Solution Approach 2:
The patent introduces a dimer of TCE as an intermediary substance that serves dual purposes: as a reaction intermediate and as a solvent. This intermediary enables the reaction system to be scaled up for mass production while simplifying the manufacturing process through self-solvent functionality
2Productivity
If conventional fluorination methods are used on chlorinated butane or butadiene, then fluorinated products can be produced, but the process is not integrated and requires separate production steps
Solution Approach 1:
The patent merges the dimerization reaction and fluorination reaction into an integrated one-pot process. The dimerization of TCE and subsequent fluorination are combined in a single reaction system, improving productivity while reducing device complexity by eliminating the need for separate production steps
Solution Approach 2:
The patent establishes continuity of useful action by making the dimer of TCE produced in the first step directly available as the solvent and reaction medium for the fluorination step. This continuous process eliminates intermediate separation and purification steps, enhancing both productivity and process integration
3Ease of manufacture
If TCE is accumulated for future use, then it can be utilized when needed, but this accumulation creates environmental problems due to TCE's harmful properties
Solution Approach 1:
The patent converts the harmful by-product TCE into a useful intermediate for producing fluorinated etching gases. By immediately utilizing TCE in the dimerization reaction rather than accumulating it, the process transforms an environmentally harmful substance into a valuable chemical feedstock, eliminating environmental issues while ensuring raw material availability
Solution Approach 2:
The patent implements self-service by using the by-product TCE directly as the starting material for the dimerization reaction. This eliminates the need for external raw material supply chains and accumulation storage, converting a harmful waste stream into a self-sufficient production system
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 enables efficient production of chlorinated and fluorinated butane or butadiene derivatives, allowing for the production of low environmental impact etching gases like hexafluorobutadiene (HFB) in a cost-effective and massive scale.
Implementation Method 1
allowing TCE to dimerize by using a dimer represented by formula (1) as a solvent at a temperature of 100° C. or higher in the presence of a free radical generating agent
Implementation Method 2
reacting the dimer of TCE with chlorine gas (Cl2) in the presence of a Lewis acid catalyst
Implementation Method 3
producing a fluorinated product containing 1.1,2,3,4,4-hexachloro-1,2,3,4-tetrafluorobutane by fluorinating the hexachlorobutadiene (C4Cl6) with a fluorinating agent
Data Source
AI summary
There is provided a method for producing chlorofluorobutane (CFB) by forming chlorinated butadiene by dimerizing trichloroethylene (TCE) and fluorinating hydrogen atoms of the chlorinated butadiene. Trichloroethylene (TCE) is dimerized by using a dimer represented by the following formula (1) as a solvent and in the presence of a free radical generating agent at a temperature of 100° C. or higher. Hexachlorobutadiene (C4Cl6) is produced from the above dimer by chlorination and dehydrochlorination reaction, and further, the chlorofluorobutane (CFB) is produced by fluorinating the hexachlorobutadiene.