Zeolite Membrane Dehydration of Formaldehyde
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Solution Overview
Problem
Existing methods for producing (meth)acrylic acid alkyl ester face challenges due to water inhibition and catalyst deterioration, particularly when using formaldehyde sources containing water, which leads to insufficient dehydration performance.
Innovation Solution
A method utilizing a zeolite membrane for vapor permeation to separate water from a water-containing source of formaldehyde, employing a separation enhancer like methyl propanoate to enhance dehydration performance, resulting in a dehydrated source of formaldehyde suitable for producing (meth)acrylic acid alkyl ester.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If formalin (aqueous formaldehyde solution) is used as raw material, then the production process is simplified, but water inhibition occurs and catalyst deterioration accelerates
Solution Approach 1:
The invention extracts and removes water from the formalin solution using a membrane separation process, isolating the harmful water component while retaining the formaldehyde for reaction. This resolves the contradiction by maintaining the ease of using formalin while eliminating the water that causes catalyst deterioration.
Solution Approach 2:
The invention changes the water content parameter of the formaldehyde source from high (formalin) to low (dehydrated formaldehyde) through membrane separation. This parameter change eliminates water inhibition and catalyst deterioration while preserving the benefits of using aqueous formaldehyde as a stable raw material.
2Stability of the object's composition
If water is present in the reaction system, then the formaldehyde source remains stable, but reaction progression is inhibited
Solution Approach 1:
The invention performs preliminary dehydration of the formaldehyde source before it enters the reaction system. By removing water in advance through membrane separation, the reaction proceeds at high rate without water inhibition, while the formaldehyde remains stable during storage and transport as an aqueous solution.
3Quantity of substance
If conventional distillation is used for dehydration, then water is removed, but the dehydration performance is insufficient
Solution Approach 1:
The invention replaces the conventional thermal distillation process with a membrane separation process. This substitution achieves superior dehydration performance and efficiency by utilizing selective permeation through the membrane rather than thermal separation, resolving the insufficient dehydration performance of conventional methods.
Solution Approach 2:
The invention employs a porous membrane with specific pore structure and hydrophilic properties to achieve efficient water separation. The membrane's porous structure enables selective water transport while retaining formaldehyde and other components, providing superior dehydration performance compared to conventional distillation.
4Manufacturing precision
If membrane dehydration is used, then dehydration performance is improved, but the process complexity increases
Solution Approach 1:
The invention uses a thin-film membrane structure that provides high dehydration performance in a compact form. The membrane's thin-film nature allows for efficient separation without requiring complex equipment, balancing improved dehydration performance with acceptable process simplicity.
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 approach achieves excellent dehydration performance, reducing water introduction into the reaction system and minimizing catalyst deterioration, thereby improving the yield and stability of (meth)acrylic acid alkyl ester production.
Implementation Method 1
a method utilizing a zeolite membrane for vapor permeation to separate water from a water-containing source of formaldehyde
Data Source
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AI summary
The present invention provides a method for dehydration of a water containing source of formaldehyde having an excellent dehydration performance, and a method for producing (meth)acrylic acid alkyl ester using a dehydrated source of formaldehyde. The present invention provides a method for dehydration of a water containing source of formaldehyde wherein water is separated from the water containing source of formaldehyde containing formaldehyde and water using a zeolite membrane wherein the water containing source of formaldehyde comprises a separation enhancer having a relative static permittivity of between 2.5 and 20 and wherein the water containing source of formaldehyde further contains methanol. The invention extends to a method for producing (meth)acrylic acid alkyl ester by reaction with carboxylic acid ester using a dehydrated source of formaldehyde obtained by a dehydration wherein water is separated from the water containing source of formaldehyde containing formaldehyde and water using a zeolite membrane.