Two-Step Hydrothermal Process for Isosorbide Yield
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Solution Overview
Problem
Current methods for producing isosorbide from sorbitol are costly and energy-intensive, often requiring corrosive acid catalysts and high vacuum levels, which lead to equipment corrosion and increased operating costs, while existing alternatives are not economically viable due to the use of large amounts of molten salt hydrates.
Innovation Solution
A two-step hydrothermal reaction process controlling temperature in the absence or presence of a transition metal salt catalyst, where the first reaction occurs at 240° C. to 285° C. and the second at 286° C. to 340° C., maximizing the formation of 1,4-sorbitan and subsequently increasing the yield of isosorbide by promoting its conversion to isosorbide at higher temperatures, thus avoiding the need for corrosive catalysts and reducing energy consumption.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If sulfuric acid is used as a catalyst and high vacuum is applied, then isosorbide can be produced through dehydration of sorbitol, but the reactor is corroded and expensive equipment is required
Solution Approach 1:
The patent replaces expensive, corrosion-resistant reactors with standard stainless steel reactors by using a non-corrosive molten salt hydrate catalyst system, effectively substituting expensive durable equipment with cheaper standard equipment that won't corrode
Solution Approach 2:
The patent changes the reaction conditions from high vacuum (10 mmHg) to atmospheric pressure by using molten salt hydrate as a catalyst, fundamentally altering the pressure parameter and eliminating the need for vacuum equipment
2Productivity
If sulfuric acid catalyst and high vacuum are used, then isosorbide production is achieved, but additional pH neutralization process and waste treatment are required
Solution Approach 1:
The patent replaces the complex multi-step process involving acid catalyst, pH neutralization, and waste treatment with a simpler single-step process using molten salt hydrate catalyst that requires no additional treatment steps
Solution Approach 2:
The patent extracts and removes the harmful acid catalyst step from the process entirely, replacing it with a non-corrosive molten salt hydrate catalyst that eliminates the need for pH neutralization and waste treatment steps
3Productivity
If high vacuum level is maintained, then isosorbide production proceeds, but large amount of energy is continuously consumed
Solution Approach 1:
The patent changes the pressure parameter from high vacuum (10 mmHg) to atmospheric pressure, eliminating the continuous energy consumption required to maintain vacuum conditions while still achieving effective isosorbide production through the molten salt hydrate catalyst
4Productivity
If molten salt hydrate is used in large amounts, then isosorbide can be produced, but the method is cost-ineffective
Solution Approach 1:
The patent optimizes the catalyst amount parameter, using only 1-10 wt% molten salt hydrate relative to sorbitol, which is sufficient to achieve high isosorbide yields while making the process economically viable
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 increases the yield of isosorbide while reducing operating costs and equipment expenses by optimizing reaction conditions, allowing for efficient water removal without energy-intensive vacuum processes and using less expensive, non-corrosive catalysts.
Implementation Method 1
a method of producing anhydrosugar alcohol using a two-step hydrothermal reaction
Implementation Method 2
which converts sugar alcohol to anhydrosugar alcohol
Implementation Method 3
subjecting an aqueous solution of sugar alcohol to a first reaction at a temperature of 240° C. to 285° C. followed by a second reaction at a temperature of 286° C. to 340° C.
Data Source
AI summary
A method for producing anhydrosugar alcohol according to the present invention can increase the yield of anhydrosugar alcohol even in the absence of a catalyst or in the presence of a small amount of a transition metal salt catalyst by controlling the temperature of a high-temperature reaction, which converts sugar alcohol to anhydrosugar alcohol, in two steps, that is, a first low-temperature reaction step and a second high-temperature reaction step.