Non-catalyzed Liquid Phase Fluorination of Tetrachloropropene
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Solution Overview
Problem
Current methods for producing E-1-chloro-3,3,3-trifluoropropene (E-1233zd) face challenges such as low reaction conversion rates, high pressure requirements, and the need for multiple reactors, especially in non-catalyzed liquid phase fluorination processes.
Innovation Solution
A continuous production process involving the fluorination of 1,1,3,3-tetrachloropropene with anhydrous hydrofluoric acid in the liquid phase without a catalyst, using a molar ratio of HF/1230za between 3 and 20, at temperatures between 50° C. and 150° C., and pressures between 1 and 20 bar, with subsequent separation and recycling operations to achieve high purity E-1233zd.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If non-catalyzed liquid phase fluorination is used, then catalyst cost is reduced, but reaction conversion rate decreases
Solution Approach 1:
The patent changes the physical state parameter of the reactants from gas phase to liquid phase, which fundamentally alters the reaction kinetics and mechanism. This liquid phase environment enables the non-catalyzed reaction to proceed at commercially viable conversion rates by modifying solvation effects, reactant concentration, and transition state stability, thereby eliminating catalyst requirements while maintaining productivity.
Solution Approach 2:
The patent employs a continuous flow reactor system where reactants are periodically introduced and processed through multiple reaction zones. This continuous periodic action allows for staged fluorination reactions that achieve high overall conversion rates without requiring catalysts, as each pass through the reactor system contributes incrementally to the total conversion.
2Productivity
If multiple reactors are used in series, then overall conversion rate increases, but device complexity increases
Solution Approach 1:
The patent merges multiple reaction stages into a single continuous flow reactor design. By combining what would traditionally require multiple discrete reactors in series into one integrated liquid phase reaction system, the patent achieves high overall conversion rates while simplifying the device structure, reducing the number of separate reactor units, and eliminating the need for complex inter-reactor piping and control systems.
3Productivity
If high pressure is applied, then reaction rate increases, but operating conditions become more restrictive
Solution Approach 1:
The patent changes the pressure parameter from high pressure conditions to ambient or near-ambient pressure operation. By utilizing liquid phase fluorination chemistry, the reaction achieves acceptable rates at much lower pressures, thereby eliminating the need for specialized high-pressure equipment and significantly improving operational flexibility and safety while maintaining productivity.
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 process achieves a high yield and selectivity under mild conditions using a single reactor, with E-1233zd purity exceeding 99.9% and stable operation over time, avoiding excessive pressure and agitation.
Implementation Method 1
the fluorination of 1,1,3,3-tetrachloropropene with anhydrous hydrofluoric acid in the liquid phase without a catalyst
Data Source
AI summary
A production process for the production of E-1-chloro-3,3,3-trifluoropropene, the process including at least one stage during which 1,3,3,3-tetrachloropropene reacts with anhydrous hydrofluoric acid in the liquid phase, in the absence of a catalyst, with an HF/1,1,3,3-tetrachloropropene molar ratio between 3 and 20 inclusive, at a temperature between 50° C. and 150° C. inclusive and an absolute pressure of between 1 and 20 bar inclusive.