Patents by Inventor Toyofumi Sakai

Toyofumi Sakai has filed for patents to protect the following inventions. This listing includes patent applications that are pending as well as patents that have already been granted by the United States Patent and Trademark Office (USPTO).

  • Publication number: 20240025835
    Abstract: The present invention provides a method capable of sufficiently reducing impurities with excellent separation efficiency even from a crystal-containing slurry that contains a low-purity mother liquor and has poor solid-liquid separation properties. The present invention relates to a method for producing a compound, the method including: a step of feeding a slurry containing crystals of the compound to a hydraulic wash column; a step of melting crystals in a crystal-containing circulation slurry discharged from the hydraulic wash column; and a step of returning a portion of a circulation liquid containing a melt obtained in the melting step to the hydraulic wash column, wherein the circulation liquid returned in the returning step in an amount of more than 30% by mass relative to 100% by mass of the melt serves as a washing liquid for crystals.
    Type: Application
    Filed: September 8, 2021
    Publication date: January 25, 2024
    Inventors: Hiroki WADA, Masashi MUKAE, Yasutaka TAKEMOTO, Toyofumi SAKAI
  • Publication number: 20240010599
    Abstract: Provided is a method for purifying a compound capable of providing a high purity compound in high yield and at low cost. The present invention relates to the method for purifying a compound using a purification apparatus, the purification apparatus including: a crystallizing unit including a crystal forming section; and a wash column including a mechanism that forcibly transfers crystals. The crystallizing unit includes N tanks connected in series, wherein N is 2 or greater, a 1st tank is a most downstream tank, a (N)th tank is a most upstream tank, at least the 1st tank is a crystallization tank including a cooling mechanism, and a 2nd and subsequent tanks are each a crystallization tank or a ripening tank. The purification apparatus includes a line that feeds a compound-containing liquid to be purified to at least one of the N tanks.
    Type: Application
    Filed: November 17, 2021
    Publication date: January 11, 2024
    Inventors: Shogo ARAI, Masashi MUKAE, Hiroki WADA, Toshiya FUKUMOTO, Takayuki MATSUDA, Toyofumi SAKAI
  • Publication number: 20240010600
    Abstract: The present invention aims to provide a compound purification apparatus capable of providing a high purity compound in high yield and at low cost.
    Type: Application
    Filed: November 17, 2021
    Publication date: January 11, 2024
    Inventors: Shogo ARAI, Masashi MUKAE, Hiroki WADA, Toshiya FUKUMOTO, Takayuki MATSUDA, Toyofumi SAKAI
  • Patent number: 10919834
    Abstract: A method for producing (meth)acrylic acid comprising: a step of obtaining a (meth)acrylic acid-containing gas by subjecting a (meth)acrylic acid production raw material to a catalytic gas phase oxidation reaction; a step of obtaining a (meth)acrylic acid-containing liquid by bringing the (meth)acrylic acid-containing gas into contact with a collection solvent and/or condensing the (meth)acrylic acid-containing gas by cooling; a step of obtaining crude (meth)acrylic acid by introducing the (meth)acrylic acid-containing liquid into a low-boiling separation column; a step of obtaining purified (meth)acrylic acid and a refining residue containing a glyoxal compound by purifying the crude (meth)acrylic acid; and a step of returning at least a part of the refining residue to the low-boiling separation column; wherein a returning position of the refining residue to the low-boiling separation column is located closer to a bottom side of the low-boiling separation column than a supply port of the (meth)acrylic acid-co
    Type: Grant
    Filed: May 22, 2018
    Date of Patent: February 16, 2021
    Assignee: NIPPON SHOKUBAI CO., LTD.
    Inventors: Yuki Kase, Toyofumi Sakai, Yasutaka Takemoto, Masashi Mukae
  • Publication number: 20200181056
    Abstract: A method for producing (meth)acrylic acid comprising: a step of obtaining a (meth)acrylic acid-containing gas by subjecting a (meth)acrylic acid production raw material to a catalytic gas phase oxidation reaction; a step of obtaining a (meth)acrylic acid-containing liquid by bringing the (meth)acrylic acid-containing gas into contact with a collection solvent and/or condensing the (meth)acrylic acid-containing gas by cooling; a step of obtaining crude (meth)acrylic acid by introducing the (meth)acrylic acid-containing liquid into a low-boiling separation column; a step of obtaining purified (meth)acrylic acid and a refining residue containing a glyoxal compound by purifying the crude (meth)acrylic acid; and a step of returning at least a part of the refining residue to the low-boiling separation column; wherein a returning position of the refining residue to the low-boiling separation column is located closer to a bottom side of the low-boiling separation column than a supply port of the (meth)acrylic acid-co
    Type: Application
    Filed: May 22, 2018
    Publication date: June 11, 2020
    Applicant: NIPPON SHOKUBAI CO., LTD.
    Inventors: Yuki KASE, Toyofumi SAKAI, Yasutaka TAKEMOTO, Masashi MUKAE
  • Patent number: 10239815
    Abstract: The objective of the present invention is to provide a method for efficiently producing acrylic acid while troubles not only in a waste oil handling after distillation of acrylic acid but also in a purification system of acrylic acid during distillation are reduced. The method for producing acrylic acid according to the present invention is characterized in comprising the step of supplying at least crude acrylic acid and an alcohol solvent to an acrylic acid distillation apparatus to distill acrylic acid, wherein a boiling point of the alcohol solvent is higher than a boiling point of acrylic acid by not lower than 50° C.
    Type: Grant
    Filed: January 26, 2016
    Date of Patent: March 26, 2019
    Assignee: NIPPON SHOKUBAI CO., LTD.
    Inventors: Toyofumi Sakai, Masashi Mukae, Yasutaka Takemoto
  • Publication number: 20180022680
    Abstract: The objective of the present invention is to provide a method for efficiently producing acrylic acid while troubles not only in a waste oil handling after distillation of acrylic acid but also in a purification system of acrylic acid during distillation are reduced. The method for producing acrylic acid according to the present invention is characterized in comprising the step of supplying at least crude acrylic acid and an alcohol solvent to an acrylic acid distillation apparatus to distill acrylic acid, wherein a boiling point of the alcohol solvent is higher than a boiling point of acrylic acid by not lower than 50° C.
    Type: Application
    Filed: January 26, 2016
    Publication date: January 25, 2018
    Applicant: Nippon Shokubai Co., Ltd.
    Inventors: Toyofumi SAKAI, Masashi MUKAE, Yasutaka TAKEMOTO
  • Patent number: 9320822
    Abstract: The present invention provides a method for manufacturing a water-absorbing resin which (i) is made of acrylic acid that is suitable for mass production of water-absorbing resin and (ii) has an excellent water-absorbing property. In the method, a polyacrylic acid (salt)-based water-absorbing resin is manufactured by sequentially carrying out predetermined monomer preparing step, polymerization step, drying step, and surface crosslinking step. An acetic acid concentration in acrylic acid or the like supplied in the monomer preparing step is in a range of 300 ppm to 10000 ppm on the acrylic acid basis, and an acetic acid concentration lowering rate defined by a predetermined formula is 35% or higher.
    Type: Grant
    Filed: February 18, 2013
    Date of Patent: April 26, 2016
    Assignee: NIPPON SHOKUBAI CO., LTD.
    Inventors: Satoshi Matsumoto, Takashi Miyamoto, Toyofumi Sakai, Yoshitake Ishii, Kunihiko Ishizaki
  • Patent number: 9029599
    Abstract: A process for producing (meth)acrylic acid comprising the step of repeating a crystallization operation “n” times to produce purified (meth)acrylic acid from crude (meth)acrylic acid, wherein: the each crystallization operation comprises a crystallizing step and a melting step; a polymerization inhibitor is not added to a (meth)acrylic acid melt obtained in the melting step of the first to n?1th crystallization operation(s) and a (meth)acrylic acid solution subjected to the crystallizing step of the second to nth crystallization operation(s); and a concentration of a polymerization inhibitor in a (meth)acrylic acid solution subjected to the crystallizing step of the first crystallization operation is adjusted so that a concentration of the polymerization inhibitor in a (meth)acrylic acid solution subjected to the crystallizing step of the nth crystallization operation is 2 ppm by mass or higher.
    Type: Grant
    Filed: September 3, 2013
    Date of Patent: May 12, 2015
    Assignee: Nippon Shokubai Co., Ltd.
    Inventors: Takashi Miyamoto, Yoshitake Ishii, Toyofumi Sakai
  • Publication number: 20150011388
    Abstract: The present invention provides a method for manufacturing a water-absorbing resin which (i) is made of acrylic acid that is suitable for mass production of water-absorbing resin and (ii) has an excellent water-absorbing property. In the method, a polyacrylic acid (salt)-based water-absorbing resin is manufactured by sequentially carrying out predetermined monomer preparing step, polymerization step, drying step, and surface crosslinking step. An acetic acid concentration in acrylic acid or the like supplied in the monomer preparing step is in a range of 300 ppm to 10000 ppm on the acrylic acid basis, and an acetic acid concentration lowering rate defined by a predetermined formula is 35% or higher.
    Type: Application
    Filed: February 18, 2013
    Publication date: January 8, 2015
    Inventors: Satoshi Matsumoto, Takashi Miyamoto, Toyofumi Sakai, Yoshitake Ishii, Kunihiko Ishizaki
  • Publication number: 20140066652
    Abstract: A process for producing (meth)acrylic acid comprising the step of repeating a crystallization operation “n” times to produce purified (meth)acrylic acid from crude (meth)acrylic acid, wherein: the each crystallization operation comprises a crystallizing step and a melting step; a polymerization inhibitor is not added to a (meth)acrylic acid melt obtained in the melting step of the first to n?1th crystallization operation(s) and a (meth)acrylic acid solution subjected to the crystallizing step of the second to nth crystallization operation(s); and a concentration of a polymerization inhibitor in a (meth)acrylic acid solution subjected to the crystallizing step of the first crystallization operation is adjusted so that a concentration of the polymerization inhibitor in a (meth)acrylic acid solution subjected to the crystallizing step of the nth crystallization operation is 2 ppm by mass or higher.
    Type: Application
    Filed: September 3, 2013
    Publication date: March 6, 2014
    Applicant: Nippon Shokubai Co., Ltd.
    Inventors: Takashi MIYAMOTO, Yoshitake ISHII, Toyofumi SAKAI
  • Patent number: 8278481
    Abstract: The present invention provides a method for effectively preventing the precipitation related to manganese acetate in the pipe for sending a polymerization inhibitor and the like, and the polymerization of (meth)acrylic acid. A first method of the present invention for producing (meth)acrylic acid, characterized in comprising steps of: producing a (meth)acrylic acid-containing gas by catalytic vapor phase oxidation reaction; and obtaining a (meth)acrylic acid-containing fluid by providing the (meth)acrylic acid-containing gas into a condensation column or an absorption column; wherein manganese acetate is used as a polymerization inhibitor; manganese acetate is dissolved into a (meth)acrylic acid aqueous solution containing not more than 10% by mass of (meth)acrylic acid, and the like, to obtain a manganese acetate aqueous solution; and the manganese acetate aqueous solution is provided into the condensation column or the absorption column.
    Type: Grant
    Filed: May 15, 2008
    Date of Patent: October 2, 2012
    Assignee: Nippon Shokubai Co., Ltd.
    Inventors: Kazuhiko Sakamoto, Naoki Serata, Toyofumi Sakai
  • Publication number: 20100130778
    Abstract: The present invention provides a method for effectively preventing the precipitation related to manganese acetate in the pipe for sending a polymerization inhibitor and the like, and the polymerization of (meth)acrylic acid. A first method of the present invention for producing (meth)acrylic acid, characterized in comprising steps of: producing a (meth)acrylic acid-containing gas by catalytic vapor phase oxidation reaction; and obtaining a (meth)acrylic acid-containing fluid by providing the (meth)acrylic acid-containing gas into a condensation column or an absorption column; wherein manganese acetate is used as a polymerization inhibitor; manganese acetate is dissolved into a (meth)acrylic acid aqueous solution containing not more than 10% by mass of (meth)acrylic acid, and the like, to obtain a manganese acetate aqueous solution; and the manganese acetate aqueous solution is provided into the condensation column or the absorption column.
    Type: Application
    Filed: May 15, 2008
    Publication date: May 27, 2010
    Inventors: Kazuhiko Sakamoto, Naoki Serata, Toyofumi Sakai
  • Patent number: 7368602
    Abstract: There is provided a process for producing (meth)acrylic acid including an absorption step of bringing a (meth)acrylic acid-containing gas obtained by a gas phase catalytic oxidation method into an absorption tower and allowing the gas to contact with an absorbent, in which absorption step a crude (meth)acrylic acid solution is withdrawn from a withdrawal outlet positioned between a supply point for the (meth)acrylic acid-containing gas and a supply point for the absorbent on the absorption tower, and then supplied to a next step. The process for producing (meth)acrylic acid makes it possible to suppress the formation of Michael adducts, thereby obtaining a (meth)acrylic acid containing solution in high yield and in high concentration.
    Type: Grant
    Filed: January 19, 2007
    Date of Patent: May 6, 2008
    Assignee: Nippon Shokubai Co., Ltd.
    Inventors: Toyofumi Sakai, Naoki Serata
  • Publication number: 20070173667
    Abstract: There is provided a process for producing (meth)acrylic acid including an absorption step of bringing a (meth)acrylic acid-containing gas obtained by a gas phase catalytic oxidation method into an absorption tower and allowing the gas to contact with an absorbent, in which absorption step a crude (meth)acrylic acid solution is withdrawn from a withdrawal outlet positioned between a supply point for the (meth)acrylic acid-containing gas and a supply point for the absorbent on the absorption tower, and then supplied to a next step. The process for producing (meth)acrylic acid makes it possible to suppress the formation of Michael adducts, thereby obtaining a (meth)acrylic acid containing solution in high yield and in high concentration.
    Type: Application
    Filed: January 19, 2007
    Publication date: July 26, 2007
    Inventors: Toyofumi Sakai, Naoki Serata