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<p>The current production of cyclohexanone oxime (CyO), an essential precursor in the global nylon-6 industry, relies on processes that utilize toxic substrates and hazardous oxidizing agents. Here we present a continuous process and reactor design, with integrated electrochemical porous solid electrolyte reactor (PSER) and packed bed reactor (PBR), for an electrolyte-free, scalable, and efficient generation of high-purity CyO product from cyclohexanone (CyH), oxygen and ammonia. By electrochemically converting oxygen into high-purity hydrogen peroxide in a PSER, followed by a direct feeding into a downstream PBR for CyH ammoximation without any intermediate purification steps, we are able to obtain electrolyte-free CyO products. In an integrated 25-cm² PSER (six times larger than our previous design) and a titanium silicate-1 filled PBR system, we successfully demonstrate high CyO product selectivity of 97.2%, high yield of 93.6%, as well as high peroxide utilization efficiency of 96.3%. By operating the PSER under 125 mA/cm<sup>2</sup>, up to 28.3 mmol/h of CyO production rate can be achieved. Efficient conversions of a broad range of other aliphatic and aromatic ketone substrates are also demonstrated in this integrated PSER-PBR reactor system.</p>

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Integrated electrochemical porous solid electrolyte reactor and packed bed reactor for efficient synthesis of nylon-6 precursor

  • 期刊论文

  • 出版模式：

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  • 发表日期：

    2026年3月5日

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  • Shou-Kun Zhang,
  • Yuge Feng,
  • Shaoyun Hao,
  • Ziang Xu,
  • Sushanth Ashokkumar,
  • Juan Wang,
  • Haotian Wang

摘要

The current production of cyclohexanone oxime (CyO), an essential precursor in the global nylon-6 industry, relies on processes that utilize toxic substrates and hazardous oxidizing agents. Here we present a continuous process and reactor design, with integrated electrochemical porous solid electrolyte reactor (PSER) and packed bed reactor (PBR), for an electrolyte-free, scalable, and efficient generation of high-purity CyO product from cyclohexanone (CyH), oxygen and ammonia. By electrochemically converting oxygen into high-purity hydrogen peroxide in a PSER, followed by a direct feeding into a downstream PBR for CyH ammoximation without any intermediate purification steps, we are able to obtain electrolyte-free CyO products. In an integrated 25-cm² PSER (six times larger than our previous design) and a titanium silicate-1 filled PBR system, we successfully demonstrate high CyO product selectivity of 97.2%, high yield of 93.6%, as well as high peroxide utilization efficiency of 96.3%. By operating the PSER under 125 mA/cm2, up to 28.3 mmol/h of CyO production rate can be achieved. Efficient conversions of a broad range of other aliphatic and aromatic ketone substrates are also demonstrated in this integrated PSER-PBR reactor system.