Trioxane Production via Liquid-Liquid Extraction and Solvent Recovery
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Solution Overview
Problem
Conventional methods for producing trioxane result in high energy consumption due to the need for large amounts of energy to separate trioxane from mixtures with formaldehyde and water, and inefficient extraction processes lead to significant energy losses and low trioxane yield.
Innovation Solution
A method involving the distillation of a formaldehyde aqueous solution in the presence of an acid catalyst, followed by liquefaction of the gas mixture and subsequent separation using two liquid/liquid extractors connected in series, allowing for energy recovery and reduced trioxane discharge into the aqueous phase, with the option to reuse solvents based on boiling points.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If distillation evaporation is used to separate trioxane from the mixture, then trioxane can be obtained, but a large amount of water is inevitably contained due to vapor-liquid equilibrium, and energy consumption is increased due to evaporation heat loss
Solution Approach 1:
The patent utilizes phase transition by condensing the vapor mixture from distillation back into liquid form, then employing liquid-liquid extraction to separate trioxane from water. This approach avoids the energy-intensive process of completely evaporating water while still achieving effective separation through the phase change and subsequent extraction steps.
Solution Approach 2:
The patent introduces an organic solvent as an intermediary substance to facilitate the separation of trioxane from water. The solvent acts as a mediator that selectively extracts trioxane from the aqueous phase, enabling separation without requiring complete evaporation of water and thus reducing energy consumption.
2Loss of energy
If liquid/liquid extraction is carried out without phase change, then energy consumption is reduced, but a large amount of trioxane is transferred to an aqueous phase, deteriorating processing efficiency
Solution Approach 1:
The organic solvent serves as an intermediary that preferentially dissolves trioxane from the aqueous mixture. By selecting a solvent with appropriate solubility characteristics, the patent achieves effective trioxane extraction into the organic phase while minimizing its transfer to the aqueous phase, thus maintaining high processing efficiency without requiring energy-intensive phase change.
Solution Approach 2:
The patent optimizes extraction parameters such as solvent-to-feed ratio, temperature, and mixing conditions to maximize trioxane transfer to the organic phase while minimizing its presence in the aqueous phase. These parameter adjustments enable efficient separation without phase change, reducing energy consumption while maintaining high productivity.
3Manufacturing precision
If a large amount of solvent is employed to extract trioxane, then trioxane solubility in water is overcome, but a large-sized distillation column is required and a great amount of energy is consumed
Solution Approach 1:
The patent optimizes the solvent quantity and extraction conditions to achieve effective trioxane separation without requiring excessive solvent. By carefully controlling extraction parameters, the patent reduces the load on subsequent distillation operations, allowing for smaller, more economical distillation columns and lower energy consumption.
Solution Approach 2:
The patent implements a solvent recovery system where the organic solvent is separated from extracted trioxane and reused in subsequent extraction operations. This recovery approach reduces the total solvent requirement over time, minimizing the size of distillation equipment needed and reducing overall energy consumption while maintaining high extraction 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 method recovers 80-85% of energy consumed in reactors and distillation columns as steam, enhances trioxane yield, and improves extraction efficiency by minimizing trioxane in the aqueous phase, while allowing for flexible solvent selection.
Implementation Method 1
preparing trioxane from a formaldehyde aqueous solution in the presence of an acid catalyst
Implementation Method 2
distilling a mixture including trioxane
Implementation Method 3
liquefying the distilled gas mixture
Implementation Method 4
mixing the liquefied liquid mixture with an extraction solvent and separating the mixture into an aqueous phase and a solvent phase
Data Source
AI summary
Disclosed is a method of producing trioxane, including: (A) preparing trioxane from a high-concentration formaldehyde aqueous solution in the presence of an acid catalyst; (B) distilling a mixture including trioxane; (C) liquefying the distilled gas mixture; (D) mixing the liquefied liquid mixture with an extraction solvent and separating the mixture into an aqueous phase and a solvent phase; (E) distilling the solvent phase to give trioxane, and mixing the aqueous phase with the extraction solvent to give a mixture, which is then separated into an aqueous phase and a solvent phase; and (F) discharging the aqueous phase separated in (E) out of the system, and recirculating the solvent phase so as to be reused in (D) and (E).