Reactor system for acetylene absorption and selective hydrogenation
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Solution Overview
Problem
Existing reactor systems face challenges in efficiently converting acetylene-rich gas streams into ethylene due to high temperatures required, which lead to coke production, catalyst deactivation, and complex acetylene purification, while also being energy-inefficient.
Innovation Solution
A reactor system comprising an absorption column, heat exchangers, and hydrogenation reactors with catalyst beds that selectively absorb and convert acetylene to ethylene using a solvent recycle loop, optimizing temperature and catalyst regeneration.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If high temperatures are used to convert acetylene-rich gas streams into ethylene, then conversion efficiency improves, but coke production increases and catalyst deactivation occurs
Solution Approach 1:
The patent changes the temperature parameter from high to low range, enabling acetylene hydrogenation to proceed at temperatures below 150°C. This parameter change resolves the contradiction by achieving acceptable conversion efficiency without the harmful effects of high temperature such as coke production and catalyst deactivation
Solution Approach 2:
The patent introduces a solvent absorption system as an intermediary between the acetylene-rich gas stream and the hydrogenation reactor. The solvent selectively absorbs acetylene from the gas stream, creating a concentrated acetylene-solvent mixture that undergoes hydrogenation at low temperatures. This intermediary approach enables efficient conversion without high temperature harm
2Productivity
If high temperatures are used for acetylene conversion, then reaction rate improves, but energy consumption increases
Solution Approach 1:
The patent fundamentally changes the temperature parameter from high to low range, achieving acetylene hydrogenation at temperatures below 150°C. This parameter change directly resolves the contradiction by maintaining acceptable reaction rates through the solvent absorption-concentration mechanism while dramatically reducing energy consumption compared to conventional high-temperature processes
Solution Approach 2:
The patent replaces thermal energy input (mechanical heating) with chemical energy input (hydrogenation reaction). The exothermic hydrogenation reaction provides the necessary activation energy, eliminating the need for continuous high-temperature heating and thus reducing external energy consumption
3Manufacturing precision
If conventional acetylene purification methods are used, then ethylene purity improves, but process complexity increases
Solution Approach 1:
The patent extracts acetylene from the gas stream using selective solvent absorption before hydrogenation. The solvent selectively takes out acetylene molecules from the mixed gas stream, forming a concentrated acetylene-solvent solution. This extraction approach simplifies the overall process by eliminating the need for complex downstream purification equipment while achieving high ethylene purity through selective conversion
Solution Approach 2:
The patent uses a solvent absorption system as an intermediary separation stage between the crude acetylene-rich gas stream and the hydrogenation reactor. This intermediary step selectively concentrates acetylene while removing other gas components, simplifying the subsequent hydrogenation process and eliminating the need for complex purification equipment downstream
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
The system achieves high acetylene conversion and ethylene selectivity with reduced safety risks and simplified process complexity, providing energy-efficient production of ethylene.
Implementation Method 1
an absorption column configured to receive an acetylene-rich gas stream flowing upwards and a cooled acetylene-lean solvent stream flowing downwards to generate an acetylene-lean gas effluent and an acetylene-rich solvent effluent
Implementation Method 2
one or more heat exchangers in fluid communication with the absorption column for receiving the acetylene-rich solvent effluent, the one or more heat exchangers being configured to transfer heat to the acetylene-rich solvent effluent to generate a heated acetylene-rich solvent stream
Implementation Method 3
at least a first one of the one or more hydrogenation reactors is configured to convert at least a portion of acetylene in the heated acetylene-rich solvent stream to ethylene in the presence of a first hydrogenation catalyst and hydrogen under first hydrogenation reaction conditions
Data Source
AI summary
A system including an absorption column configured to receive an acetylene-rich gas stream flowing upwards and a cooled acetylene-lean solvent stream flowing downwards to generate an acetylene-lean gas effluent and an acetylene-rich solvent effluent, one or more heat exchangers for receiving the acetylene-rich solvent effluent, the one or more heat exchangers being configured to transfer heat to the acetylene-rich solvent effluent to generate a heated acetylene-rich solvent stream, and one or more hydrogenation reactors each having one or more catalyst beds, wherein at least a first one of the one or more hydrogenation reactors is configured to convert at least a portion of acetylene in the heated acetylene-rich solvent stream to ethylene in the presence of a first hydrogenation catalyst and hydrogen under first hydrogenation reaction conditions to generate a first hydrogenation effluent including ethylene and a first acetylene-lean solvent effluent.