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).

  • Patent number: 8093437
    Abstract: 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: Grant
    Filed: January 19, 2007
    Date of Patent: January 10, 2012
    Assignee: Asahi Kasei Chemicals Corporation
    Inventors: Shinsuke Fukuoka, Hironori Miyaji, Hiroshi Hachiya, Kazuhiko Matsuzaki
  • Patent number: 8071819
    Abstract: 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: Grant
    Filed: December 28, 2006
    Date of Patent: December 6, 2011
    Assignee: Asahi Kasei Chemicals Corporation
    Inventors: Shinsuke Fukuoka, Hironori Miyaji, Hiroshi Hachiya, Kazuhiko Matsuzaki
  • Patent number: 8058465
    Abstract: 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: Grant
    Filed: November 17, 2006
    Date of Patent: November 15, 2011
    Assignee: Asahi Kasei Chemicals Corporation
    Inventors: Shinsuke Fukuoka, Hironori Miyaji, Hiroshi Hachiya, Kazuhiko Matsuzaki
  • Patent number: 8049028
    Abstract: 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: Grant
    Filed: December 15, 2006
    Date of Patent: November 1, 2011
    Assignee: Asahi Kasei Chemicals Corporation
    Inventors: Shinsuke Fukuoka, Hironori Miyaji, Hiroshi Hachiya, Kazuhiko Matsuzaki
  • Patent number: 8044226
    Abstract: 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: Grant
    Filed: July 23, 2009
    Date of Patent: October 25, 2011
    Assignee: Asahi Kasei Chemicals Corporation
    Inventors: Shinsuke Fukuoka, Hironori Miyaji, Hiroshi Hachiya, Kazuhiko Matsuzaki
  • Patent number: 8044167
    Abstract: 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: Grant
    Filed: July 23, 2009
    Date of Patent: October 25, 2011
    Assignee: Asahi Kasei Chemicals Corporation
    Inventors: Shinsuke Fukuoka, Hironori Miyaji, Hiroshi Hachiya, Kazuhiko Matsuzaki
  • Patent number: 7884251
    Abstract: 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: Grant
    Filed: September 12, 2005
    Date of Patent: February 8, 2011
    Assignee: Asahi Kasei Chemicals Corporation
    Inventors: Shinsuke Fukuoka, Hironori Miyaji, Hiroshi Hachiya, Kazuhiko Matsuzaki
  • Patent number: 7812189
    Abstract: 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: Grant
    Filed: August 24, 2005
    Date of Patent: October 12, 2010
    Assignee: Asahi Kasei Chemicals Corporation
    Inventors: Shinsuke Fukuoka, Hiroshi Hachiya, Kazuhiko Matsuzaki, Hironori Miyaji
  • Patent number: 7799939
    Abstract: 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: Grant
    Filed: September 5, 2006
    Date of Patent: September 21, 2010
    Assignee: Asahi Kasei Chemicals Corporation
    Inventors: Hironori Miyaji, Shinsuke Fukuoka, Hiroshi Hachiya
  • Patent number: 7777067
    Abstract: 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: Grant
    Filed: July 11, 2005
    Date of Patent: August 17, 2010
    Assignee: Asahi Kasei Chemicals Corporation
    Inventors: Shinsuke Fukuoka, Hiroshi Hachiya, Kazuhiko Matsuzaki
  • Patent number: 7658817
    Abstract: 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: Grant
    Filed: November 29, 2005
    Date of Patent: February 9, 2010
    Assignee: Asahi Kasei Chemicals Corporation
    Inventors: Shinsuke Fukuoka, Hiroshi Hachiya, Kazuhiko Matsuzaki
  • Publication number: 20090326257
    Abstract: 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: Application
    Filed: November 30, 2006
    Publication date: December 31, 2009
    Inventors: Shinsuke Fukuoka, Hironori MIyaji, Hiroshi Hachiya, Kazuhiko Matsuzaki
  • Patent number: 7622601
    Abstract: 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: Grant
    Filed: October 12, 2005
    Date of Patent: November 24, 2009
    Assignee: Asahi Kasei Chemicals Corporation
    Inventors: Shinsuke Fukuoka, Hironori Miyaji, Hiroshi Hachiya, Kazuhiko Matsuzaki
  • Publication number: 20090287014
    Abstract: 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: Application
    Filed: July 23, 2009
    Publication date: November 19, 2009
    Inventors: Shinsuke FUKUOKA, Hironori Miyaji, Hiroshi Hachiya, Kazuhiko Matsuzaki
  • Publication number: 20090287012
    Abstract: 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: Application
    Filed: July 23, 2009
    Publication date: November 19, 2009
    Inventors: Shinsuke FUKUOKA, Hironuri Miyaji, Hiroshi Hachiya, Kazuhiko Matsuzaki
  • Publication number: 20090270656
    Abstract: 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: Application
    Filed: January 26, 2007
    Publication date: October 29, 2009
    Applicant: ASAHI KASEI CHEMICALS CORPORATION
    Inventors: Shinsuke Fukuoka, Hironori Miyaji, Hiroshi Hachiya, Kazuhiko Matsuzaki
  • Publication number: 20090264670
    Abstract: 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: Application
    Filed: December 14, 2006
    Publication date: October 22, 2009
    Inventors: Shinsuke Fukuoka, Hironori Miyaji, Hiroshi Hachiya, Kazuhiko Matsuzaki
  • Publication number: 20090253939
    Abstract: 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: Application
    Filed: November 17, 2006
    Publication date: October 8, 2009
    Applicant: Asahi Kasei Chemicals Corporation
    Inventors: Shinsuke Fukuoka, Hironori Miyaji, Hiroshi Hachiya, Kazuhiko Matsuzaki
  • Publication number: 20090209724
    Abstract: 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: Application
    Filed: November 30, 2006
    Publication date: August 20, 2009
    Applicant: ASAHI KASEI CHEMICALS CORPORATION
    Inventors: Shinsuke Fukuoka, Hironori Miyaji, Hiroshi Hachiya, Kazuhiko Matsuzaki
  • Publication number: 20090163734
    Abstract: 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: Application
    Filed: December 12, 2006
    Publication date: June 25, 2009
    Applicant: ASAHI KASEI CHEMICALS CORPORATION
    Inventors: Shinsuke Fukuoka, Hironori Miyaji, Hiroshi Hachiya, Kazuhiko Matsuzaki