2-chloro-5-chloromethylpyridine (CCMP) is the intermediate of imidacloprid technical drug. The traditional kettle production line with 10000 tonne/year occupies huge production resources due to the parallel amplification of multiple sets of equipment involved in dissociation, chlorination, addition, cyclization and other processes. The huge production lines, including plants, utilities, reactors, storage tanks, metering tanks, post-treatment and separation of reactants, and supporting DCS automatic control, cannot be reduced in quantity, so the investment cannot be reduced.
From the perspective of safety and investment, hundreds of sets of measuring tanks, transfer tanks and reaction pots (generally 5-20 kiloliter containers and reaction facilities) are required, and automatic control facilities worth more than ten million yuan should be equipped at the same time. The greater risk is that due to the parallel amplification of processes, the turnover of raw materials in production is massive, and safety risks always exists.
With in-depth research and development and effective practice, the single set of metallic or silicon carbide (SiC) microreactor production line with a flow rate of 10000 ~ 20000 tons/year (the main equipment covers an area of about 10 square meters) becomes mature. Combined with professional companies' post-treatment separation and purification technology, the production line of 1000 tons of pesticide intermediates and raw drugs per month has made an essential leap. First, the total investment cost of the project decreased by 15~20%; Second, the investment in plant, public works, land occupation and labour decreased by 60~20%; Third, the distance operation, automatic regulation and parking of data became available; Fourth, the dependence on technicians and operators will be minimized.
Taking the synthesis of 2-chloro-5-chloromethylpyridine as an example, in order to achieve a monthly production capacity of 1000 tons/month, the feeding amount of the whole process from dissociation to cyclization is about 250000 tons/year. Zhian technology has used microreactor technology to realize the feasibility of four synthetic processes, including addition, chlorination and cyclization. Similarly, the cracking process can also realize large flow continuous flow dissociation with trails and attempts.
Based on the existing design specifications, the investment in the CCMP production line with a monthly output of 1000 tons/month is more than 80 million yuan. However, with the facilities of Zhongshan microreactor, the total investment can be reduced by 10 million yuan.
The difference between new equipment and traditional equipment is directly reflected by the following aspects:
1. The traditional process needs 150~200 sets of reaction reactors with capacity of 5000~20000L; The main equipment of microreactor covers an area of <600 square meters.
2. Traditional supporting 200~300 sets of 3~6 m3 metering tanks; The microreaction process can greatly reduce the turnover of raw materials by 5~8%.
3. The investment in refrigeration, water supply, public pipelines, plant and automatic control of supporting equipment has been significantly reduced;
4. The production process is controllable. The production can start and stop according to the inventory demand and reduce the occupation of raw materials and working capital.
Due to the adjustment of the chemical industry, the synthetic facilities should have advantages, such as short return cycles, practicality, advancement and intelligence, to attract the favour of famous chemical enterprises. In addition to the hardware performance, the intelligent microreactor is very important, which depends on the extended function of the DCS system. At present, the investment cost of Zhongshan Zhian 10000 ton intelligent industrial microreaction synthesis line is about 300 yuan/ton/minute.
With its unique design concept, Zhongshan pays attention to the pharmaceutical industry. With the help of mature DCs technology of central control, we provide new equipment and process package operation services.
