Patents by Inventor Shinsuke Fukuoka
Shinsuke Fukuoka 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).
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Patent number: 8093437Abstract: The invention provides an apparatus and process for producing a diol by taking a cyclic carbonate and an aliphatic monohydric alcohol as starting materials, continuously feeding the starting materials into column A, carrying out reactive distillation in column A, continuously withdrawing a low boiling point reaction mixture containing a produced dialkyl carbonate and the aliphatic monohydric alcohol from an upper portion of column A, continuously withdrawing a high boiling point reaction mixture containing a produced diol from a lower portion of column A, continuously feeding the high boiling point reaction mixture into distillation column C, distilling off material having a lower boiling point than that of the diol contained in the high boiling point reaction mixture as a column top component and a side cut component so as to obtain a column bottom component, continuously feeding the column bottom component into column C, and obtaining the diol.Type: GrantFiled: January 19, 2007Date of Patent: January 10, 2012Assignee: Asahi Kasei Chemicals CorporationInventors: Shinsuke Fukuoka, Hironori Miyaji, Hiroshi Hachiya, Kazuhiko Matsuzaki
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Patent number: 8071819Abstract: The invention provides an apparatus and process for producing high-purity diol by taking cyclic carbonate and aliphatic monohydric alcohol as starting materials, continuously feeding the starting materials into column A, carrying out reactive distillation in column A, continuously withdrawing a low boiling point reaction mixture containing a produced dialkyl carbonate and the aliphatic monohydric alcohol from an upper portion of column A, continuously withdrawing a high boiling point reaction mixture containing a produced diol from a lower portion of column A, continuously feeding the high boiling point reaction mixture into distillation column C, distilling off material having a lower boiling point than that of the diol contained in the high boiling point reaction mixture AB as a column top component and/or a side cut component so as to obtain a column bottom component, continuously feeding the column bottom component into distillation column E, and obtaining the diol.Type: GrantFiled: December 28, 2006Date of Patent: December 6, 2011Assignee: Asahi Kasei Chemicals CorporationInventors: Shinsuke Fukuoka, Hironori Miyaji, Hiroshi Hachiya, Kazuhiko Matsuzaki
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Patent number: 8058465Abstract: A process for industrially producing dialkyl carbonate and a diol continuously through a reactive distillation system is disclosed. The process includes the steps of taking a cyclic carbonate and an aliphatic monohydric alcohol as starting materials, continuously feeding the starting materials into a continuous multi-stage distillation column in which a catalyst is present, carrying out reaction and distillation simultaneously in the column, continuously withdrawing a low boiling point reaction mixture containing the produced dialkyl carbonate from an upper portion of the column in a gaseous form, and continuously withdrawing a high boiling point reaction mixture containing the diol from a lower portion of the column in a liquid form. According to the present invention, there is provided a specific continuous multi-stage distillation column having a specified structure, and a production process using this continuous multi-stage distillation column.Type: GrantFiled: November 17, 2006Date of Patent: November 15, 2011Assignee: Asahi Kasei Chemicals CorporationInventors: Shinsuke Fukuoka, Hironori Miyaji, Hiroshi Hachiya, Kazuhiko Matsuzaki
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Patent number: 8049028Abstract: It is an object of the present invention to provide a specific apparatus and process for using a single distillation column on a low boiling point reaction mixture containing a large amount of a dialkyl carbonate and an aliphatic monohydric alcohol produced through a reactive distillation process of taking a cyclic carbonate and the aliphatic monohydric alcohol as starting materials, continuously feeding the starting materials into a continuous multi-stage distillation column in which a homogeneous catalyst is present, and carrying out reaction and distillation simultaneously in the column, so as to separate the low boiling point reaction mixture by distillation into a column top component BT having the aliphatic monohydric alcohol as a main component thereof and a column bottom component BB having the dialkyl carbonate as a main component thereof stably for a prolonged period of time industrially.Type: GrantFiled: December 15, 2006Date of Patent: November 1, 2011Assignee: Asahi Kasei Chemicals CorporationInventors: Shinsuke Fukuoka, Hironori Miyaji, Hiroshi Hachiya, Kazuhiko Matsuzaki
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Patent number: 8044226Abstract: A high-purity diphenyl carbonate, wherein the diphenyl carbonate is unsubstituted or substituted with a lower hydrocarbon, and has a halogen content of not more than 0.1 ppm, a content of an intermediate boiling point material of not more than 100 ppm, and a content of by-products having a higher boiling point than that of said diphenyl carbonate of not more than 100 ppm. A specific industrially useful process for the production of a high-purity diaryl carbonate in which a diaryl carbonate having low contents of intermediate boiling point and high boiling point impurities is produced is disclosed. As a starting material, a reaction mixture containing an alkyl aryl carbonate obtained through a transesterification reaction between a dialkyl carbonate and an aromatic monohydroxy compound is used. The process in which separation by distillation is carried out uses three distillation columns in a specified order.Type: GrantFiled: July 23, 2009Date of Patent: October 25, 2011Assignee: Asahi Kasei Chemicals CorporationInventors: Shinsuke Fukuoka, Hironori Miyaji, Hiroshi Hachiya, Kazuhiko Matsuzaki
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Patent number: 8044167Abstract: An aromatic polycarbonate that is obtained by transesterification between a high-purity diphenyl carbonate and an aromatic dihydroxy compound. A specific industrially useful process for the production of a high-purity diaryl carbonate in which a diaryl carbonate having low contents of intermediate boiling point and high boiling point impurities is produced is disclosed. As a starting material, a reaction mixture containing an alkyl aryl carbonate obtained through a transesterification reaction between a dialkyl carbonate and an aromatic monohydroxy compound is used. The process in which separation by distillation is carried out uses three distillation columns in a specified order. Moreover, it is particularly preferable if a reactive distillation column and the three distillation columns, each of which has a specified structure, and the three distillation columns are each operated under specified distillation conditions.Type: GrantFiled: July 23, 2009Date of Patent: October 25, 2011Assignee: Asahi Kasei Chemicals CorporationInventors: Shinsuke Fukuoka, Hironori Miyaji, Hiroshi Hachiya, Kazuhiko Matsuzaki
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Patent number: 7884251Abstract: It is an object of the present invention to provide a specific industrial separation process that enables an alcohol to be separated out efficiently and stably for a prolonged period of time from a large amount of a low boiling point reaction mixture containing a by-produced alcohol when mass-producing aromatic carbonates on an industrial scale by subjecting a dialkyl carbonate and an aromatic monohydroxy compound to transesterification reaction in a reactive distillation column in which a catalyst is present. Although there have been various proposals regarding processes for the production of aromatic carbonates by means of a reactive distillation method, these have all been on a small scale and short operating time laboratory level, and there have been no disclosures whatsoever on a specific process or apparatus enabling mass production on an industrial scale to be carried out stably for a prolonged period of time.Type: GrantFiled: September 12, 2005Date of Patent: February 8, 2011Assignee: Asahi Kasei Chemicals CorporationInventors: Shinsuke Fukuoka, Hironori Miyaji, Hiroshi Hachiya, Kazuhiko Matsuzaki
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Patent number: 7812189Abstract: According to the present invention, there are provided a high boiling point material separating column A and a diphenyl carbonate purifying column B each comprising a continuous multi-stage distillation column having specified structures, and there is provided a specific process that enables a high-purity diphenyl carbonate which is important as a raw material of a high-quality and high-performance polycarbonate to be produced stably for a prolonged period of time on an industrial scale of not less than 1 ton/hr from a reaction mixture containing the diphenyl carbonate using an apparatus in which these two continuous multi-stage distillation columns are connected together.Type: GrantFiled: August 24, 2005Date of Patent: October 12, 2010Assignee: Asahi Kasei Chemicals CorporationInventors: Shinsuke Fukuoka, Hiroshi Hachiya, Kazuhiko Matsuzaki, Hironori Miyaji
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Patent number: 7799939Abstract: It is an object of the present invention to provide, for a case of producing a dialkyl carbonate and a diol from a cyclic carbonate and an aliphatic monohydric alcohol, a process that simultaneously satisfies the cyclic carbonate conversion being high, the selectivities for the dialkyl carbonate and diol to be produced being high, and a high-purity diol having a high UV transmittance and a low aldehyde content being obtained without carrying out complicated treatment such as feeding water into a diol distillation purification step.Type: GrantFiled: September 5, 2006Date of Patent: September 21, 2010Assignee: Asahi Kasei Chemicals CorporationInventors: Hironori Miyaji, Shinsuke Fukuoka, Hiroshi Hachiya
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Patent number: 7777067Abstract: It is an object of the present invention to provide, for the case of continuously producing aromatic carbonates containing a diaryl carbonate as a main product by taking an alkyl aryl carbonate as a starting material, which is obtainable through a transesterification reaction between a dialkyl carbonate and an aromatic monohydroxy compound, using a continuous multi-stage distillation column in which a catalyst is present, and continuously feeding the starting material into the continuous multi-stage distillation column, a specific process that enables the diaryl carbonate to be produced with high selectivity and high productivity stably for a prolonged period of time on an industrial scale of not less than 1 ton per hour.Type: GrantFiled: July 11, 2005Date of Patent: August 17, 2010Assignee: Asahi Kasei Chemicals CorporationInventors: Shinsuke Fukuoka, Hiroshi Hachiya, Kazuhiko Matsuzaki
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Patent number: 7658817Abstract: An industrial evaporation apparatus having a specified structure in which there are guides that do not themselves have a heat source, a flow path controlling member having a function of making the liquid fed onto a perforated plate from a liquid receiving port flow mainly from a peripheral portion toward a central portion of the perforated plate is provided in a liquid feeding zone, and formula (1) to (5), or formula (1) to (10), or formula (1) to (12), are satisfied.Type: GrantFiled: November 29, 2005Date of Patent: February 9, 2010Assignee: Asahi Kasei Chemicals CorporationInventors: Shinsuke Fukuoka, Hiroshi Hachiya, Kazuhiko Matsuzaki
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Publication number: 20090326257Abstract: It is an object of the present invention to provide a specific process that enables dialkyl carbonates and diols to be produced on an industrial scale of not less than 2 ton/hr and not less than 1.3 ton/hr respectively with high selectivity and high productivity stably for a prolonged period of time through a reactive distillation system of taking cyclic carbonates and aliphatic monohydric alcohols as starting materials, continuously feeding the starting materials into a continuous multi-stage distillation column in which a catalyst is present, and carrying out reaction and distillation simultaneously in the column. Although there have been many proposals regarding processes for the production of the dialkyl carbonates and the diols through a reactive distillation method, these have all been on a small scale and short operating time laboratory level, and there have been no disclosures whatsoever on a specific process or apparatus enabling mass production on an industrial scale.Type: ApplicationFiled: November 30, 2006Publication date: December 31, 2009Inventors: Shinsuke Fukuoka, Hironori MIyaji, Hiroshi Hachiya, Kazuhiko Matsuzaki
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Patent number: 7622601Abstract: A specific industrially useful process for the production of a high-purity diaryl carbonate in which a diaryl carbonate having low contents of intermediate boiling point and high boiling point impurities is produced is disclosed. As a starting material, a reaction mixture containing an alkyl aryl carbonate obtained through a transesterification reaction between a dialkyl carbonate and an aromatic monohydroxy compound is used. The process in which separation by distillation is carried out uses three distillation columns in a specified order. Moreover, it is particularly preferable if a reactive distillation column and the three distillation columns, each of which has a specified structure, and the three distillation columns are each operated under specified distillation conditions.Type: GrantFiled: October 12, 2005Date of Patent: November 24, 2009Assignee: Asahi Kasei Chemicals CorporationInventors: Shinsuke Fukuoka, Hironori Miyaji, Hiroshi Hachiya, Kazuhiko Matsuzaki
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Publication number: 20090287014Abstract: An aromatic polycarbonate that is obtained by transesterification between a high-purity diphenyl carbonate and an aromatic dihydroxy compound. A specific industrially useful process for the production of a high-purity diaryl carbonate in which a diaryl carbonate having low contents of intermediate boiling point and high boiling point impurities is produced is disclosed. As a starting material, a reaction mixture containing an alkyl aryl carbonate obtained through a transesterification reaction between a dialkyl carbonate and an aromatic monohydroxy compound is used. The process in which separation by distillation is carried out uses three distillation columns in a specified order. Moreover, it is particularly preferable if a reactive distillation column and the three distillation columns, each of which has a specified structure, and the three distillation columns are each operated under specified distillation conditions.Type: ApplicationFiled: July 23, 2009Publication date: November 19, 2009Inventors: Shinsuke FUKUOKA, Hironori Miyaji, Hiroshi Hachiya, Kazuhiko Matsuzaki
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Publication number: 20090287012Abstract: A high-purity diphenyl carbonate, wherein the diphenyl carbonate is unsubstituted or substituted with a lower hydrocarbon, and has a halogen content of not more than 0.1 ppm, a content of an intermediate boiling point material of not more than 100 ppm, and a content of by-products having a higher boiling point than that of said diphenyl carbonate of not more than 100 ppm. A specific industrially useful process for the production of a high-purity diaryl carbonate in which a diaryl carbonate having low contents of intermediate boiling point and high boiling point impurities is produced is disclosed. As a starting material, a reaction mixture containing an alkyl aryl carbonate obtained through a transesterification reaction between a dialkyl carbonate and an aromatic monohydroxy compound is used. The process in which separation by distillation is carried out uses three distillation columns in a specified order.Type: ApplicationFiled: July 23, 2009Publication date: November 19, 2009Inventors: Shinsuke FUKUOKA, Hironuri Miyaji, Hiroshi Hachiya, Kazuhiko Matsuzaki
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Publication number: 20090270656Abstract: It is an object of the present invention to provide a specific apparatus and process for industrially producing a high-purity diol by taking a cyclic carbonate and an aliphatic monohydric alcohol as starting materials. Moreover, it is an object to thus provide a specific industrial apparatus and industrial production process that are inexpensive and, for example, enable the high-purity diol to be produced in an amount of not less than 1 ton/hr, preferably not less than 2 tons/hr, more preferably not less than 3 tons/hr, stably for a prolonged period of time (e.g. not less than 1000 hours, preferably not less than 3000 hours, more preferably not less than 5000 hours).Type: ApplicationFiled: January 26, 2007Publication date: October 29, 2009Applicant: ASAHI KASEI CHEMICALS CORPORATIONInventors: Shinsuke Fukuoka, Hironori Miyaji, Hiroshi Hachiya, Kazuhiko Matsuzaki
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Publication number: 20090264670Abstract: It is an object of the present invention to provide a solution by providing a specific process that enables a dialkyl carbonate and a diol to be produced on an industrial scale of not less than 2 ton/hr and not less than 1.3 ton/hr respectively with high selectivity and high productivity stably for a prolonged period of time through a reactive distillation system of taking a cyclic carbonate and an aliphatic monohydric alcohol as starting materials, continuously feeding the starting materials into a continuous multi-stage distillation column in which a catalyst is present, and carrying out reaction and distillation simultaneously in the column. Although there have been many proposals regarding processes for the production of the dialkyl carbonate and the diol through a reactive distillation method, these have all been on a small scale and short operating time laboratory level, and there have been no disclosures whatsoever on a specific process or apparatus enabling mass production on an industrial scale.Type: ApplicationFiled: December 14, 2006Publication date: October 22, 2009Inventors: Shinsuke Fukuoka, Hironori Miyaji, Hiroshi Hachiya, Kazuhiko Matsuzaki
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Publication number: 20090253939Abstract: It is an object of the present invention to provide a specific process that enables a dialkyl carbonate and a diol to be produced on an industrial scale of not less than 2 ton/hr and not less than 1.3 ton/hr respectively with high selectivity and high productivity stably for a prolonged period of time through a reactive distillation system of taking a cyclic carbonate and an aliphatic monohydric alcohol as starting materials, continuously feeding the starting materials into a continuous multi-stage distillation column in which a catalyst is present, and carrying out reaction and distillation simultaneously in the column. Although there have been many proposals regarding processes for the production of the dialkyl carbonate and the diol through the reactive distillation method, these have all been on a small scale and short operating time laboratory level, and there have been no disclosures whatsoever on a specific process or apparatus enabling mass production on an industrial scale.Type: ApplicationFiled: November 17, 2006Publication date: October 8, 2009Applicant: Asahi Kasei Chemicals CorporationInventors: Shinsuke Fukuoka, Hironori Miyaji, Hiroshi Hachiya, Kazuhiko Matsuzaki
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Publication number: 20090209724Abstract: It is an object of the present invention to provide a specific process that enables a high-quality high-performance aromatic polycarbonate having excellent mechanical properties and no discoloration to be produced industrially in a large amount (e.g. not less than 1 ton/hr) stably for a prolonged period of time (e.g. not less than 1000 hours, preferably not less than 3000 hours, more preferably not less than 5000 hours) from a dialkyl carbonate and an aromatic dihydroxy compound.Type: ApplicationFiled: November 30, 2006Publication date: August 20, 2009Applicant: ASAHI KASEI CHEMICALS CORPORATIONInventors: Shinsuke Fukuoka, Hironori Miyaji, Hiroshi Hachiya, Kazuhiko Matsuzaki
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Publication number: 20090163734Abstract: It is an object of the present invention to provide a specific process that enables a high-purity diphenyl carbonate required for producing a high-quality high-performance aromatic polycarbonate to be produced industrially in a large amount (e.g. not less than 1 ton/hr) stably for a prolonged period of time (e.g. not less than 1000 hours, preferably not less than 3000 hours, more preferably not less than 5000 hours) from a cyclic carbonate and a phenol.Type: ApplicationFiled: December 12, 2006Publication date: June 25, 2009Applicant: ASAHI KASEI CHEMICALS CORPORATIONInventors: Shinsuke Fukuoka, Hironori Miyaji, Hiroshi Hachiya, Kazuhiko Matsuzaki