New Solvent Method of Prepn for CuPc with yield 99%.pptx

8/10/2019 New Solvent Method of Prepn for CuPc with yield 99%.pptx

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Filter Press Used to Collect the CrudeFormed Product Specification of Crude

CuPc in Industry


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Spin Flash Dryer Used to Dry Crude CuPcin Industry


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PROBLEMS OF MANUFACTURING CRUDE CuPc

1.YieldThe yield of reaction is max 90% based on copper chlorideused (see List of Patents). There are therefore about 10 %of the reagents used are disposed as waste.

2. Environmental EffectMost of the waste of the production of crude CuPc (11,000tons/yr) is precipitated using Na 2S and then is buriedunderground


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MARKET DEMAND for Copper PhthalocyanineWorld production of this product is over 110,000

tons/year while the gap between the world demandand the supply according to Business Analyst forAsahi Songwon Colors Ltd for 2011 is 19,000 tons /year.

PRODUCTION COUNTRIESCrude CuPc was used to be produced in Japan,Europe and America but now it has been shifted tomainly China and India due to lower labor cost and

also mainly as the waste regulations of thesecountries are not strictly followed.


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COST OF RAW MATERIALS USED(Jan 2011)

Phthalic anhydride

Cuprous Chloride

Urea

Ammoniummolybdate

CuPc (just rawmaterials cost)

FOB Price of CuPc(from Baiyan China)

$ 1,500 / MT

$ 6,565 / MT

$ 350 / MT

$ 24,000 / MT

$ 3,517 / MT

$ 5,760 /MT


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Calculation Material Weight used for 1

MT CuPcUnit Price / MT Cost

CuCl 191 kg $ 6,565 $ 1,254.00

Phthalic Anhydride 1143 kg $ 1,500 $ 1,714.50

Urea 1390 kg $ 350 $ 487.00

Catalyst 2.60 kg $ 24,000 $ 62.40

Total Cost CuPc $ 3,517.90 / MT


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Profit

Then Profit would be calculated as follows:

(5000 MT x $5.76) - $20m - $0.2m - $0.36m + (10% x 5000 MT x$5.76) = $8.24m + $2.88m

$11.12m/yr (before depreciation of building, Interest & Tax)

The profit should be more than this as the saving cost for thewaste treatment has not been added to this amount.


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Solutions to the Problems

Adding a small amount of another co catalyst would improve the yieldtremendously up to 99.9%

The co-catalyst could be added at the same time as other reagentsbefore the reaction starts or in the middle of the reaction before thetemperature reaches 120 C.

The general chemical formula of this chemical is a complex of X-fattyacid ester sodium salt


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New Method of Preparation of Crude CuPc

Apparatus: Round bottom flask 1000 ml Liebig condensor Dean stark Thermocouple Homo mixer Flask receiver

Heating mantel Glass Beaker 250 ml Analytical balance 0.001 gr Vacuum pump Oven Filter cloth Buchner flask Buchner funnel Glass Beaker 5000 ml Thermometer


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New Method of Preparation of CrudeCuPc

Chemicals for Preparation of CuPc:

Urea : 170 gr Phthalic Anhydride : 130 gr Cuprous Chloride : 21.60 gr Catalyst Ammonium molybdate : 0.30 gr Solvent alkyl benzene : 180 gr Co-catalyst : 0.50 gr

(substituted fatty acid ester sodium salt)

Chemicals for washing crude:

Sulfuric acid 60% NP-10 Water


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New Method of Preparation of CrudeCuPc

Preparation of crude is divided into 2 parts :

Method of Preparation for crude Washing of Crude

New Method of preparation of CRUDE

Set the reactor which consists of a round bottom flask,dean stark and liebig condenser with cool water running.

Pour the solvent into the reactor. Set the homo mixer with 80 rpm speed. Heat the solvent up to 110 - 120 C, then add all other materials into the flask. The mixture will change color several times with ammonia is evolved vigorously. During the

first 1 hour the mixture will have several color changes until it finally turns blue when thetemperature reaches about 180C.

Record the reaction temperature at every hour . Add 100 ml solvent at the second and fourth hours. Stop the reaction after 7 hour, filter it and then dry in the oven at 100 C until it dries.


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Product Specification of New Crude CuPc usingAmerican Standard Test Method

Parameter

Purity Moisture Content

Water Soluble Matter Alcohol Soluble Matter pH Conductivity Total Grit Iron Sand Fiber Free Copper Content PCB

Specification

97 % min 1 % max

1.5 % max 2.0 % max 4 - 8 800 mho 300 ppm max 20 pieces max /100 g 30 pieces max / 100 g Trace 3000 ppm max 0.1 ppm max


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Value of the New Method . The economic benefit obtained from the research if successful would be the extra yield of

9% plus the saving cost of waste treatment.

If the price of crude CuPc per kg is $7.00/Kg per Dec 2014 so for the medium sizemanufacturer which usually produces 5000 MT/year the added profit would roughly be

= 450000 kg x $7.00 + saving cost of waste treatment per year= about $3.5 million/year.

. Green Environment : reduced waste from 10 % to 1%

Besides copper phthalocyanine, there are other many metals phthalocyanines which arealso produced in industry due to their specific uses such as ZnPc, Al Pc, SiPc and SnPc whichare used for photodynamic therapy (PDT) for cancer and others. All these metalphthalocyanines are produced with yield much lower than 90%, some are even below 10%.If the proposed method above is successful then it would almost certain be valuable forother metals phthalocyanines preparation.


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References Asahi Songwon Annual Report 2010-11 US Patent 3188318 (1965) : 79% Yield based on CuCl used US Patent 3985767 (1976) : 76.9% Yield based on CuCl used US Patent 5393339 (1995) : 85% Yield based on CuCl used, US Patent 5910585 (1999) : 89% Yield based on CuCl used The Porphyrin Handbook, edited by KM Kadish et al, vol 19, p114, 2003. 85-90% Yield

CN Patent 1974577 (2007) : 85% Yield based on CuCl used US Patent 4000157 (1976) US Patent 5393339 (1995) : 85% Yield based on CuCl used EP 0672728 B1 (1999) US Patent 5810585 (1999) Japanese Patent 2001181525 (2001) Japanese Patent 2001181529 (2001) Japanese Patent 2002012789 (2002) CN Patent 1428377 (2003) CN Patent 101538415 (2009)

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New Solvent Method of Prepn for CuPc with yield 99%.pptx