1. A process to produce a purified slurry stream comprising furan-2,5-dicarboxylic acid (FDCA), said process comprising:
(a) oxidizing in an primary oxidation zone 5-(hydroxymethyl)furfural (5-HMF) in the presence of a solvent stream comprising acetic acid, an oxidizing gas stream comprising oxygen, and a catalyst system to produce a carboxylic acid composition comprising furan-2,5-dicarboxylic acid (FDCA); wherein said catalyst system comprises cobalt in a range from about 500 ppm to about 6000 ppm with respect to the weight of the liquid in the primary oxidation zone, manganese in an amount ranging from about 2 ppm to about 600 ppm by weight with respect to the weight of the liquid in the primary oxidation zone, and bromine in an amount ranging from about 300 ppm to about 4500 ppm by weight with respect to the weight of the liquid in the primary oxidation zone; and wherein the yield of furan-2,5-dicarboxylic acid is greater than 50%; wherein said primary oxidation zone comprises at least on oxidation reactor operated at a temperature between 132\xb0 C. to 180\xb0 C.;
(b) routing said carboxylic acid composition to a liquid displacement zone to produce a displaced mother liquid stream and a low impurity slurry stream; and
(c) routing said low impurity slurry stream to a secondary oxidation zone to form a purified slurry stream; wherein said purified slurry stream comprises FDCA.
2. A process according to claim 1 wherein said displaced mother liquid stream is routed to a purge zone to generate a recovered solvent stream comprising solvent and catalyst.
3. A process according to claim 1 wherein the yield of furan-2,5-dicarboxylic acid (FDCA) is greater than 60%.
4. A process according to claim 1 wherein an offgas from said primary oxidation zone is routed to an oxidizer offgas treatment zone.
5. A process according to claim 1 wherein the yield of furan-2,5-dicarboxylic acid is greater than 70%.
6. A process according to claim 1 wherein the yield of furan-2,5-dicarboxylic acid is greater than 80%.
7. A process according to claim 1 wherein the yield of furan-2,5-dicarboxylic acid is greater than 90%.
The claims below are in addition to those above.
All refrences to claim(s) which appear below refer to the numbering after this setence.
1. A waste heat recovery system for a split-cycle engine including a compression cylinder, a power cylinder, and a gas passage interconnecting the compression cylinder and the power cylinder, and an air storage tank connected to the gas passage by a branch port, the waste heat recovery system comprising: a heat exchange unit; an air compressor device in fluid communication with the heat exchange unit; a waste heat input for receiving waste heat from the engine in fluid communication with the heat exchange unit; an ambient air intake connected to the air compressor device for drawing air into the air compressor device; and a compressed air outlet member on the air compressor device for delivering compressed air from the air compressor device to the air storage tank for later use in a combustion process in the power cylinder of the engine; means for driving the air compressor via engine waste heat.
2. The waste heat recovery system of claim 1, wherein an engine coolant subsystem is in communication with the heat exchange unit, and engine coolant is circulated from the engine through the heat exchange unit.
3. The waste heat recovery system of claim 1, wherein an engine exhaust subsystem is in communication with the heat exchange unit to pass engine exhaust gas through the heat exchange unit.
4. The waste heat recovery system of claim 1, including a circulation line for circulating heat exchange medium between the heat exchange unit and the air compressor device.
5. The waste heat recovery system of claim 4, wherein the heat exchange medium is one of a refrigerant and water.
6. The waste heat recovery system of claim 4, including a condenser operatively connected to the circulation line.
7. The waste heat recovery system of claim 4, including a pump operatively connected to the circulation line for pumping the heat exchange medium through the circulation line.
8. The waste heat recovery system of claim 1, wherein the compressed air is stored in the air storage tank.
9. The waste heat recovery system of claim 1, including a first valve for controlling flow into the storage tank, a second valve for controlling flow out of the storage tank, and a third valve for controlling flow across the gas passage, wherein the compressed air simultaneously charges the storage tank and drives the power cylinder when the first and second valves controlling flow into and out of the storage tank are open and the third valve controlling flow across the gas passage is closed.
10. The waste heat recovery system of claim 1, wherein the engine is operable to initiate said combustion process in the power cylinder shortly after the power piston reaches its top dead center (TDC) position.
11. The waste heat recovery system of claim 1, operable to inject fuel into the gas passage downstream of the branch port to mix with compressed air prior to entering the power cylinder.
12. The waste heat recovery system of claim 11, wherein the engine is operable to initiate said combustion process in the power cylinder shortly after the power piston reaches its top dead center (TDC) position.
13. A method of recovering waste heat from a split-cycle engine including a compression cylinder, a power cylinder, a gas passage interconnecting the compression cylinder and the power cylinder, and an air storage tank connected to the gas passage by a branch port, the method comprising:
providing an air compression system including an air compressor device;
delivering waste heat from the engine to the air compression system;
utilizing energy from the waste heat to power the air compressor device; and
delivering waste-heat generated compressed air from the air compressor device to the air storage tank for use in a combustion process in the power cylinder of the split-cycle engine.
14. The method of claim 13, including the step of:
providing a heat exchange unit to utilize the waste heat to change a heat exchange medium from a liquid phase to a gas phase.
15. The method of claim 14, wherein the step of delivering waste heat from the engine to the air compression system includes:
circulating engine coolant through the engine and the heat exchange unit.
16. The method of claim 14, wherein the step of delivering waste heat from the engine to the air compression system includes:
passing engine exhaust gases from the engine through the heat exchange unit.
17. The method of claim 16, including the step of:
venting the exhaust gases to the atmosphere through an engine exhaust system after the exhaust gases are passed through the heat exchange unit.
18. The method of claim 14, including the step of:
circulating the heat exchange medium through the heat exchange unit and the air compressor device.
19. The method of claim 18, wherein the step of circulating the heat exchange medium includes:
pumping the heat exchange medium.
20. The method of claim 18, including the step of:
providing a condenser downstream of the air compressor device to change the heat exchange medium from the gas phase to the liquid phase.
21. The method of claim 20, including the step of:
venting excess heat from the condenser is to the atmosphere.
22. The method of claim 13, including the step of:
drawing ambient air into the air compressor device through an ambient air intake.
23. The method of claim 13, including the step of:
delivering waste-heat generated compressed air to the engine through a compressed air outlet operatively connected to an engine air intake.
24. The method of claim 13, including the step of:
storing waste-heat generated compressed air from the compression cylinder in the air storage tank of the split-cycle engine.
25. The method of claim 13, including the steps of:
charging the air storage tank of the split-cycle engine with waste-heat generated compressed air from the compression cylinder; and
simultaneously driving the power cylinder with waste-heat generated compressed air from the air storage tank.
26. The method of claim 13, further comprising:
initiating said combustion process in the power cylinder shortly after the power piston reaches its top dead center (TDC) position.
27. The method of claim 13, further comprising:
injecting fuel into the gas passage downstream of the branch port to mix with compressed air prior to entering the power cylinder.
28. The method of claim 27, further comprising:
initiating said combustion process in the power cylinder shortly after the power piston reaches its top dead center (TDC) position.