TWI760878B - 用於醛醇縮合反應之設備 - Google Patents
用於醛醇縮合反應之設備 Download PDFInfo
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- 238000005882 aldol condensation reaction Methods 0.000 title claims abstract description 23
- 238000006243 chemical reaction Methods 0.000 claims abstract description 49
- 239000003054 catalyst Substances 0.000 claims abstract description 47
- ZTQSAGDEMFDKMZ-UHFFFAOYSA-N Butyraldehyde Chemical compound CCCC=O ZTQSAGDEMFDKMZ-UHFFFAOYSA-N 0.000 claims description 48
- XLYOFNOQVPJJNP-UHFFFAOYSA-N water Substances O XLYOFNOQVPJJNP-UHFFFAOYSA-N 0.000 claims description 32
- 238000005575 aldol reaction Methods 0.000 claims description 25
- PYLMCYQHBRSDND-UHFFFAOYSA-N 2-ethyl-2-hexenal Chemical compound CCCC=C(CC)C=O PYLMCYQHBRSDND-UHFFFAOYSA-N 0.000 claims description 15
- 239000010410 layer Substances 0.000 claims description 12
- HEMHJVSKTPXQMS-UHFFFAOYSA-M Sodium hydroxide Chemical compound [OH-].[Na+] HEMHJVSKTPXQMS-UHFFFAOYSA-M 0.000 claims description 9
- 239000012044 organic layer Substances 0.000 claims description 7
- 239000007864 aqueous solution Substances 0.000 claims 3
- 230000000694 effects Effects 0.000 abstract description 8
- 239000002351 wastewater Substances 0.000 abstract description 2
- 239000000376 reactant Substances 0.000 description 17
- 238000004519 manufacturing process Methods 0.000 description 8
- 150000001299 aldehydes Chemical class 0.000 description 7
- 238000000034 method Methods 0.000 description 7
- 238000006722 reduction reaction Methods 0.000 description 3
- 238000003860 storage Methods 0.000 description 3
- HSJKGGMUJITCBW-UHFFFAOYSA-N 3-hydroxybutanal Chemical compound CC(O)CC=O HSJKGGMUJITCBW-UHFFFAOYSA-N 0.000 description 2
- 239000002253 acid Substances 0.000 description 2
- 150000007513 acids Chemical class 0.000 description 2
- 150000001298 alcohols Chemical class 0.000 description 2
- 150000001336 alkenes Chemical class 0.000 description 2
- 230000015572 biosynthetic process Effects 0.000 description 2
- 230000000052 comparative effect Effects 0.000 description 2
- 238000005516 engineering process Methods 0.000 description 2
- 239000007791 liquid phase Substances 0.000 description 2
- SLCVBVWXLSEKPL-UHFFFAOYSA-N neopentyl glycol Chemical compound OCC(C)(C)CO SLCVBVWXLSEKPL-UHFFFAOYSA-N 0.000 description 2
- 239000002245 particle Substances 0.000 description 2
- 238000005191 phase separation Methods 0.000 description 2
- 238000003786 synthesis reaction Methods 0.000 description 2
- 230000002194 synthesizing effect Effects 0.000 description 2
- XTVRLCUJHGUXCP-UHFFFAOYSA-N 3-methyleneheptane Chemical compound CCCCC(=C)CC XTVRLCUJHGUXCP-UHFFFAOYSA-N 0.000 description 1
- 239000003377 acid catalyst Substances 0.000 description 1
- 239000000654 additive Substances 0.000 description 1
- 125000000217 alkyl group Chemical group 0.000 description 1
- 229910052799 carbon Inorganic materials 0.000 description 1
- 125000004432 carbon atom Chemical group C* 0.000 description 1
- 238000003889 chemical engineering Methods 0.000 description 1
- 150000001875 compounds Chemical class 0.000 description 1
- 238000006482 condensation reaction Methods 0.000 description 1
- 238000010924 continuous production Methods 0.000 description 1
- 238000010586 diagram Methods 0.000 description 1
- 238000005265 energy consumption Methods 0.000 description 1
- -1 for example Substances 0.000 description 1
- 239000007789 gas Substances 0.000 description 1
- 239000002920 hazardous waste Substances 0.000 description 1
- 238000007037 hydroformylation reaction Methods 0.000 description 1
- 239000003446 ligand Substances 0.000 description 1
- 239000000463 material Substances 0.000 description 1
- 239000002184 metal Substances 0.000 description 1
- 239000000203 mixture Substances 0.000 description 1
- JRZJOMJEPLMPRA-UHFFFAOYSA-N olefin Natural products CCCCCCCC=C JRZJOMJEPLMPRA-UHFFFAOYSA-N 0.000 description 1
- 230000003647 oxidation Effects 0.000 description 1
- 238000007254 oxidation reaction Methods 0.000 description 1
- 239000004014 plasticizer Substances 0.000 description 1
- 238000004886 process control Methods 0.000 description 1
- 239000002994 raw material Substances 0.000 description 1
- 238000011084 recovery Methods 0.000 description 1
- 238000000926 separation method Methods 0.000 description 1
- 239000002904 solvent Substances 0.000 description 1
- 239000002918 waste heat Substances 0.000 description 1
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Abstract
提供一種用於醛醇縮合反應之設備,在低成本下具有高生產率。特定而言,根據本發明之用於醛醇縮合反應之設備,經由防止當增大設施規模時駐留時間增加導致之轉化率下降,具有高生產率之功效,使得升高催化劑濃度及溫度之條件可行,且與習知設備比較下在相同產率時具有催化劑使用量最小化之功效。此外,使得增大設施規模所需之成本可被最小化,無添加裝置,例如個別之泵,且所製造有害廢水之量可被最小化。
Description
以下之揭示係關於一種用於醛醇縮合反應之設備。
一般而言,醛醇縮合反應係指如下過程:多種烯烴及合成氣體(CO/H2
)在金屬催化劑及配位基存在下經由已知為羰化反應(oxo reaction)的氫甲醯化反應,生成具有較烯烴多一個碳原子的直鏈及支鏈醛,其中藉由醛醇縮合反應自該烯烴生成α及β不飽和醛。
於醛醇等之縮合反應之後合成之不飽和醛,可經由氧化或還原反應轉化成含有長烷基之多種酸及醇,且這些醇及酸被使用作為溶劑、添加劑、及多種塑化劑等之原料。
為了改良習知之醛醇縮合反應,韓國專利公開第10-2004-0111873 號揭示在關於一種新戊二醇之製備方法之技術中,在串聯設置之作為二或多個反應器之連續攪拌槽反應器中,進行醛醇縮合反應。此外,韓國專利公開第10-1996-0047519 號揭示在關於一種新戊二醇之製備方法之技術中,於醛醇縮合反應器後有提供未反應醛之回收塔,因此循環未反應物質以增進反應效率。
並且,當使用塞流反應器(PFR)時,為了所需程度之轉化率及產率,反應器長度通常應被增至70公尺或更高,且甚至 100公尺或更高,且因此設法得到空間為困難的,且用以控制反應器條件之設備太多且變得複雜。
此外,由醛系化合物經由醛醇縮合反應合成不飽和醛,對於控制其反應熱已有限制。迄今,使用熱交換器以控制溫度至所需溫度之方法已使用,其中同時不斷地循環反應物,其由於大量消耗額外熱能,有不良之熱效率,且其之設施規模變得大且複雜。
本發明之一實施態樣係關於提供一種用於醛醇縮合反應之設備,其在低成本下具有高生產率。
本發明之一特定實施態樣係關於提供一種用於醛醇縮合反應之設備,其經由防止由於增大設施規模時駐留時間增加所導致之轉化率下降,而具有高生產率。
本發明之另一特定實施態樣係關於提供一種用於醛醇縮合反應之設備,其使得升高催化劑濃度及溫度之條件可行,且與習知設備比較下為相同產率時可使催化劑使用量最小化。
本發明之另一特定實施態樣係關於提供一種用於醛醇縮合反應之設備,其可使增大設施規模所需之成本最小化,甚至無添加裝置,例如個別之泵。
本發明之再另一特定實施態樣係關於提供一種用於醛醇縮合反應之設備,其可使所製造有害廢水之量最小化。
於一般方面,一種用於醛醇縮合反應之設備,其由正丁醛經由醛醇縮合反應製造2-乙基己烯醛,該設備包括:連續攪拌槽反應器10,正丁醛及催化劑流入其內;塞流反應器20,正丁醛、該催化劑及產物自該連續攪拌槽反應器10流入其內;油-水分離器30,該產物及該催化劑自該塞流反應器20流入其內,且其將催化劑分離至水層,且將產物分離至有機層;及熱交換器40,用以將分離出之產物之熱傳送至流入該連續攪拌槽反應器10之正丁醛,其中在油-水分離器30中分離至水層之催化劑係直接流入該連續攪拌槽反應器10且被循環。
於本發明之一例示性實施態樣中,於熱交換器40中,正丁醛可被由油-水分離器30排出之產物加熱,係由室溫加熱至70至170℃。
根據本發明之一例示性實施態樣之用於醛醇縮合反應之設備,可再包括2-乙基己烯醛之儲存單元,經由熱交換器40而損失熱至正丁醛之產物流入其內。
於本發明之一例示性實施態樣中,連續攪拌槽反應器10中之轉化率可為30至60%。
於本發明之一例示性實施態樣中,塞流反應器20中轉化率可為95%或更高。
根據本發明之一例示性實施態樣之用於醛醇縮合反應之設備,可再包括溫度控制器,用以控制連續攪拌槽反應器10或塞流反應器20之反應溫度至80至200℃。
根據本發明之一例示性實施態樣之用於醛醇縮合反應之設備,可再包括駐留時間制器,用以控制連續攪拌槽反應器10 或塞流反應器20之駐留時間至0.1至30 分鐘。
於本發明之一例示性實施態樣中,催化劑可包括選自NaOH水溶液及KOH水溶液中之任一者或多者。
其他特徵及方面將由以下之詳細敘述、圖式及申請專利範圍明顯得知。
在下文中,根據本發明之用於醛醇縮合反應之設備將經由參考附圖被詳細敘述。
本說明書中例示之圖式以實例之方式提供,以使本發明之概念可被充分傳達至熟習此技術之人士。因此,本發明不被限制至所提供之圖式,但可被以許多不同形式體現,且圖式可被誇大,以清楚闡明本發明之精神。
本說明書中使用之技術用語及科學用語,具有被熟習本發明所屬技術領域之人士了解之一般意義,除非另有定義;且在以下說明及所附圖式中,將省略對於已知功能的描述以及使本發明要旨變得不清楚的構型。
此處使用之單數型用語可被預期為亦包括複數型,除非有另外指出。
此處使用之單位%若無特別提及係指重量%,除非另有定義。
迄今,當意欲由正丁醛使用醛醇縮合反應製造2-乙基己烯醛時,尤其,當生產設施及設備為了大量生產被增加時,有一些限制,亦即當與增大產量之前比較下,在反應器內之全部區域引發並進行反應為非常困難的,轉化率不高,且必須設法得到非常大空間,用以獲得所需或較高之轉化率。
因此,本發明提供一種用於醛醇縮合反應之設備,當然即使當大幅增大產量以使所需之輸出被滿足時,其在與習知設備比較下亦不需要設法得到一額外大空間,其在反應期間使分散於水層中有機層粒子之平均直徑最小化,且使得反應器內部之全部區域保持於反應狀態,且不只有高反應區域及高效率,但即使建立增大之大量生產系統,亦可達到低的不確定度及高準確度之製程控制之功效。此外,本發明在與習知設備比較下,於相同輸出量時具有顯著降低之能源消耗、及高熱效率所致之優異之經濟可行性。
根據本發明之用於醛醇縮合反應之設備,其由正丁醛經由醛醇縮合反應製造2-乙基己烯醛,包括:連續攪拌槽反應器(CSTR) 10,有正丁醛及催化劑流入其內;塞流反應器(PFR) 20,有正丁醛、該催化劑及產物自該連續攪拌槽反應器10流入其內;油-水分離器30,有產物及催化劑自塞流反應器20流入其內,且其將催化劑分離至水層,且將產物分離至有機層;及熱交換器40,用以傳送產物之熱至流入連續攪拌槽反應器10之正丁醛,其中於油-水分離器30中分離至水層之催化劑係直接流入連續攪拌槽反應器10且被循環。
於本發明中,於油-水分離器30中分離至水層之催化劑係直接流入連續攪拌槽反應器10且被循環,且作為產物之2-乙基己烯醛之高熱不被作為廢熱而捨棄,但被傳送至作為反應物之正丁醛,因此與習知系統相較下,即使於較大規模大量生產系統中,本發明具有以高轉化率及高產率合成2-乙基己烯醛之功效。因此,於本發明中,催化劑使得連續攪拌槽反應器10、塞流反應器20及油-水分離器30能不斷地循環。
“於油-水分離器30中分離至水層之催化劑,係直接流入連續攪拌槽反應器10且被循環”之事實,意指經由油-水分離器30循環之催化劑不經由供給管線(其中反應物被傳送)流入反應器,但係流入連續攪拌槽反應器10。亦即,於本發明中,須被循環之催化劑不以催化劑與反應物之混合狀態流入供給管線,以被傳送而流入連續攪拌槽反應器10 。在以前,當經由油-水分離器30循環之催化劑與反應物混合,然後經由混合供給管線流入連續攪拌槽反應器10時,尤其對於因應產量增加而具有大體積之反應區域之一大量生產系統而言,實際上難以準確控制製程條件,且因此,於反應器內部之全部區域中,要保持一反應狀態,其中在反應期間分散於水層之有機層粒子之平均直徑為最小化,係困難的。此可導致轉化率及產率之降低,亦即輸出量之降低。由反應物經由催化劑合成一產物之醛醇縮合反應,較佳在具有符合製程條件之環境的反應器內發生,且當反應在不符合條件之混合供給管線等中發生時,控制製程為困難的,不確定度被增加,且難以使得轉化率達到所需之程度或更高,此係由於多種變數之作用。
被經由熱交換器40排出之正丁醛流入連續攪拌槽反應器10中,其之狀態在與流入熱交換器40之前之正丁醛比較下為具有增高之熱。再者,經由熱交換器40被排出之2-乙基己烯醛,係以與在流入熱交換器40之前之2-乙基己烯醛比較下具有降低之熱之狀態之被排出。此處,被排出之2-乙基己烯醛可被貯存於2-乙基己烯醛之儲存單元中。亦即,根據本發明之一例示性實施態樣之用於醛醇縮合反應之設備,可再包括2-乙基己烯醛之儲存單元,有透過熱交換器40而損失熱至正丁醛之產物流入其內。
透過熱交換器40自產物接受熱之正丁醛之溫度,可視反應條件而調整,但較佳在熱交換器40中,正丁醛可被自油-水分離器30排出之產物加熱且從室溫加熱至70至170℃。
關於連續攪拌槽反應器10或塞流反應器20之反應溫度,已知之文獻可被參考,且作為實際例子之溫度可為80至200℃,特定而言為100至160℃。亦即,根據本發明之一例示性實施態樣之用於醛醇縮合反應之設備,可再包括溫度控制器,用以控制反應器10及20中每一者之反應溫度至70至170℃。
尤其,如上述,由於產物與反應物交換熱,溫度自動達到所需之反應溫度,且於溫度控制器中所欲控制之溫度範圍,在與習知範圍比較下係降低的,以使得能控制更準確之溫度。
如上述,根據本發明之用於醛醇縮合反應之設備,可自正丁醛透過連續製程製造2-乙基己烯醛,促使具有高熱(其來自醛醇縮合反應期間產生之熱)之產物更容易趨向室溫而平衡,且同時有效地供給反應所需之熱至反應物。
由於連續攪拌槽反應器10 為化學工程領域中已知的,可參考已知之文獻被設計,但在更有助於增進轉化率之方面,反應區域體積較佳為0.6至1 m3
。
塞流反應器20可參考已知之文獻被容易地設計,且作為實例,反應器之內部可被被提供有螺旋形連續構件,具有沿著管之長度方向固定的或非固定的螺距,但當然本發明不被限制至此。
油-水分離器30 為一用於相分離之裝置,用以將包括催化劑及產物之混合物進行相分離,從而使有機層在上部分及水層在下部分,且其之細節可參考已知之文獻。作為產物之2-乙基己烯醛存在於有機層中且催化劑存在於水層中,且2-乙基己烯醛透過油-水分離器30之上方管排出,且催化劑透過油-水分離器30之下方管排出。
連續攪拌槽反應器10中之轉化率較佳可在30至60%之範圍內,且特定而言在35至55%之範圍內,且塞流反應器20中之轉化率可在95% 或更高之範圍內,特定而言97% 或更高,且更特定而言97%至99.9%。當連續攪拌槽反應器10及塞流反應器20中之轉化率分別符合上述之範圍時,最終結果可為95% 或更高(較佳97% 或更高)之高轉化率及高產率。
亦即,用於醛醇縮合反應之設備依照一較佳例示性實施態樣可再包括駐留時間控制器,以使連續攪拌槽反應器10之轉化率可為30至60%,特定而言35至55%,且塞流反應器20之轉化率可為95% 或更高,特定而言97% 或更高,且更特定而言97%至99.9%。
駐留時間控制器可控制連續攪拌槽反應器10 或塞流反應器20中之駐留時間,駐留時間可被適當控制以使轉化率符合如上述者,且例如駐留時間可被控制至0.1至30 分鐘,特定而言0.5至5 分鐘。然而,此被敘述作為一較佳實施例,且本發明不被解讀為必定被限制至此。
關於連續攪拌槽反應器10 或塞流反應器20之反應壓力,已知之文獻可被參考,且作為實例,壓力可在1至50 巴之範圍內,且特定而言2至10 巴。亦即,根據本發明之一例示性實施態樣之用於醛醇縮合反應之設備可再包括壓力控制器,用以控制反應器10及20中每一者之壓力至上述範圍。
於本發明之一例示性實施態樣中,鹼催化劑及酸催化劑二者皆可被用作催化劑,例如,更佳為鹼催化劑,且作為鹼催化劑之實例包括選自NaOH水溶液、KOH水溶液等中之任一者或多者之催化劑。然而,此為一特定及較佳實例,本發明不被解讀為必定被限制至此。
於本發明中,反應物於液相中經由催化劑反應以合成產物,反應發生於液相中,且包括反應物、催化劑、及/或產物之溶液可經由泵 50傳送。泵 50 之位置沒有很大的限制,且作為實例,泵 50可被提供在連續攪拌槽反應器10與塞流反應器20之間,如圖 1所示者。然而,此為一特定施實例,本發明不被解讀為必定被限制至此。
在連續攪拌槽反應器10或塞流反應器20中,對於包括反應物、催化劑,及/或產物之溶液之流速,已知之文獻可被參考,且作為實例,流速可在50至200 m3
/hr之體積流速範圍內。亦即,根據本發明之一例示性實施態樣之用於醛醇縮合反應之設備可再包括流速控制器,用以控制於反應器10與20中每一者之溶液流速至上述範圍。
在下文中,本發明將經由實施例詳細敘述,然而,實施例被用以更詳細敘述本發明,且本發明之範疇不被限制至以下之實施例。
(實施例 1)
設計反應設備,如圖 1 所示,且2-乙基己烯醛以下表 1所示條件,自正丁醛透過醛醇縮合反應製造出,且測量轉化率。
經由油-水分離器30 循環之催化劑不與反應物混合,且直接流入連續攪拌槽反應器10中。
[比較實施例 1]
以與實施例1相同方式進行,只除了經由油-水分離器30循環之催化劑,係以與反應物混合之狀態經由傳送反應物之供給管線流入連續攪拌槽反應器10中。
[表 1]
CSTR(連續攪拌槽反應器) | PFR(塞流反應器) | |||
入口 | 出口 | 入口 | 出口 | |
溫度(°C) | 120.3 | 134 | 134 | 148 |
壓力 (巴) | 6.5 | 6.5 | 6.5 | 6.51 |
質量流速 (kg/hr) | 78723.9 | 78723.9 | 78723.9 | 78723.9 |
體積流速 (m3 /hr) | 92.75 | 94.13 | 94.13 | 94.78 |
反應器體積(m3 ) | 0.6 | 1.37 | ||
直徑 (mm) | 750 | - | ||
高度(mm) | 1,140 | - | ||
駐留時間 (秒) | 23 | 52 | ||
轉化率(%) | 50 | 96.9 | ||
總轉化率(%) | 97.8 |
結果確認,實施例 1為97.8%之高轉化率,而比較實施例 1為95.3%之相對低之轉化率。因此發現較佳者為,須透過油-水分離器30循環之催化劑,不經由供給管線(其中反應物被傳送)以與反應物混合之狀態流入連續攪拌槽反應器10,亦即,須透過油-水分離器30循環之催化劑,不與反應物混合且直接流入連續攪拌槽反應器10。
根據本發明之用於醛醇縮合反應之設備具有於低成本下高生產率之功效。
特定而言,根據本發明之用於醛醇縮合反應之設備,透過防止當增大設施規模時駐留時間增加所導致之轉化率下降,具有高生產率之功效。
此外,根據本發明之用於醛醇縮合反應之設備使得升高催化劑濃度及溫度之條件可行,且與習知設備比較下為相同產率時可使催化劑使用量最小化。
此外,根據本發明之用於醛醇縮合反應之設備具有一功效,可使增大設施規模所需之成本最小化,甚至無添加裝置,例如個別之泵。
此外,根據本發明之用於醛醇縮合反應之設備,具有使所製造有害廢水之量最小化之功效。
10:連續攪拌槽反應器
20:塞流反應器
30:油-水分離器
40:熱交換器
50:泵
圖1為製程流程圖,其示意性例示根據本發明之用於醛醇縮合反應之設備。
10:連續攪拌槽反應器
20:塞流反應器
30:油-水分離器
40:熱交換器
50:泵
Claims (7)
- 一種用於醛醇縮合反應之設備,其由正丁醛經由醛醇縮合反應製造2-乙基己烯醛,該設備包含:連續攪拌槽反應器10,正丁醛及催化劑流入其內;塞流反應器20,正丁醛、該催化劑及產物自該連續攪拌槽反應器10流入其內;油-水分離器30,該產物及該催化劑自該塞流反應器20流入其內,且其將該催化劑分離至水層,將該產物分離至有機層;以及熱交換器40,用以傳送該經分離產物之熱至流入該連續攪拌槽反應器10之正丁醛,其中在該油-水分離器30中分離至水層的催化劑係直接流入該連續攪拌槽反應器10且被循環。
- 如請求項1所述之用於醛醇縮合反應之設備,其中,在該熱交換器40中,正丁醛被自該油-水分離器30排出之產物加熱且從室溫加熱至70至170℃。
- 如請求項1所述之用於醛醇縮合反應之設備,其中該連續攪拌槽反應器10中之轉化率為30至60%。
- 如請求項3所述之用於醛醇縮合反應之設備,其中該塞流反應器20中之轉化率為95%或更高。
- 如請求項1所述之用於醛醇縮合反應之設備,更包含溫度控制器,用以控制該連續攪拌槽反應器10或該塞流反應器20之反應溫度至80至200℃。
- 如請求項1所述之用於醛醇縮合反應之設備,更包含駐留時間控制器,用以控制該連續攪拌槽反應器10或該塞流反應器20之駐留時間至0.1至30分鐘。
- 如請求項1所述之用於醛醇縮合反應之設備,其中該催化劑為鹼性水溶液,包括選自NaOH水溶液及KOH水溶液中之任一者或多者。
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