2,3,3,3-Tetrafluoropropene Production via Organic Co-Feed
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Solution Overview
Problem
Current methods for producing hydrofluoroolefins like 2,3,3-tetrafluoropropene (HFO-1234yf) face challenges such as high costs due to hazardous and expensive hydrogen gas handling, low yields, and significant byproduct formation, which necessitate an economically viable and efficient production process.
Innovation Solution
A process involving a starting composition of compounds CX2=CCl-CH2X, CX3-CCl=CH2, and CX3-CHCl-CH2X, with co-feed organic compounds, is heated to form a vapor phase composition, then contacted with a fluorinating agent, utilizing catalysts like chromium oxide to produce 2,3,3-trifluoropropene, followed by dehydrochlorination to achieve 2,3,3-tetrafluoropropene, reducing polymerization and catalyst deactivation.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If hydrogen gas is used in the fluorination process, then high yield of HFO-1234yf is achieved, but handling costs and safety hazards increase significantly
Solution Approach 1:
The invention changes the chemical parameters by substituting hydrogen gas with organic co-feed compounds (such as alcohols, ethers, or esters) that can serve as hydrogen donors in the fluorination reaction. This parameter change maintains high productivity while eliminating the safety and cost issues associated with hydrogen gas handling.
Solution Approach 2:
The invention employs inexpensive organic co-feed compounds that can be easily handled and disposed of, replacing expensive and hazardous hydrogen gas. These organic compounds serve their hydrogen donor function and can be replaced with simple, low-cost materials that do not require specialized handling infrastructure.
2Productivity
If pyrolysis of methyl chloride and tetrafluoroethylene is used, then fluorinated olefins are produced, but yield is low and carbon black deactivates the catalyst
Solution Approach 1:
The invention converts the harmful effect of carbon black formation into a beneficial process by using organic co-feed compounds that eliminate carbon black production entirely. The organic compounds serve as hydrogen donors without producing carbon-containing byproducts that would deactivate the catalyst, thus maintaining continuous high-yield production.
Solution Approach 2:
The organic co-feed compounds act as intermediary substances that facilitate the fluorination reaction by providing hydrogen atoms without introducing carbon contamination. These intermediaries enable the reaction to proceed with high yield while protecting the catalyst from deactivation.
3Productivity
If starting reagent is heated to form vapor phase composition, then reaction efficiency improves, but polymerization of starting reagent increases
Solution Approach 1:
The organic co-feed compounds serve as intermediary substances that interfere with the polymerization pathway of the starting reagent. By providing an alternative reaction pathway through hydrogen donation, these intermediaries prevent the formation of polymerized byproducts while maintaining the benefits of vapor-phase heating for reaction efficiency.
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 enhances reaction efficiency, reduces byproduct formation, and lowers costs by using co-feed compounds to minimize polymerization and catalyst deactivation, achieving high conversion and selectivity of HFO-1234yf production.
Implementation Method 1
The starting composition is heated to form a vapor phase composition
Implementation Method 2
contacted with a fluorinating agent, utilizing catalysts like chromium oxide to produce 2,3,3-trifluoropropene
Implementation Method 3
followed by dehydrochlorination to achieve 2,3,3-tetrafluoropropene
Data Source
AI summary
The present invention relates, in part, to the discovery that, during the fluorination of certain fluoroolefin starting reagents, oligomerization/polymerization of such reagents reduces the conversion process and leads to increased catalyst deactivation. The present invention also illustrates that vaporizing such starting reagents in the presence of one or more organic co-feed reduces such oligomerization/polymerization and improves catalytic stability.