Alkane Aromatization Reactor Benzene Reduction via Transalkylation
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Solution Overview
Problem
Aromatic-rich streams produced from alkane aromatization processes often contain high levels of benzene, which are regulated out of gasoline and other products, necessitating benzene reduction to facilitate efficient processing.
Innovation Solution
Co-feeding or recycling benzene into the aromatization reactor with the alkane-containing feed stream, using a catalyst such as a molecular sieve, to reduce net benzene production by promoting additional reactions that minimize benzene output.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If alkane-containing feed stream is contacted with aromatization catalyst to produce aromatic hydrocarbons, then aromatic-rich product stream is obtained, but high levels of benzene are produced which must be removed
Solution Approach 1:
The patent applies this principle by co-feeding benzene into the aromatization reactor, where it undergoes transalkylation reactions to form C7+ aromatic hydrocarbons. The harmful benzene that needs to be removed is converted into beneficial higher aromatic products, simultaneously increasing productivity and reducing benzene content in the product stream
Solution Approach 2:
The patent changes the composition parameter of the feed stream by adding benzene (at least 5 wt% based on total feed weight) to the alkane-containing feed stream. This parameter change triggers transalkylation reactions that consume benzene and produce C7+ aromatics, resolving the contradiction between aromatic production and benzene removal
2Object-generated harmful factors
If benzene is removed from aromatic-rich stream to meet regulations, then product quality improves, but additional processing steps and costs are required
Solution Approach 1:
Rather than removing benzene through additional separation steps, the patent converts benzene into valuable C7+ aromatic hydrocarbons through transalkylation reactions in the aromatization reactor. This eliminates the need for separate benzene removal units and reduces overall process complexity
Solution Approach 2:
The aromatization reactor performs a dual function: it produces aromatic hydrocarbons while simultaneously consuming excess benzene through transalkylation reactions. The system serves itself by using the benzene byproduct as a reactant to form desired higher aromatic products, eliminating the need for external benzene removal equipment
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 process effectively reduces benzene production to less than 5 wt.% in the reactor effluent, enabling the production of aromatic hydrocarbons with lower benzene content, making the product stream more suitable for further processing operations like gasoline and para-xylene production.
Implementation Method 1
contacting the feed stream with an aromatization catalyst to produce an effluent stream comprising C7+ aromatic hydrocarbons
Data Source
AI summary
Embodiments disclosed herein related to processes and systems for alkane aromatization. In some embodiments, the process includes merging a benzene-containing stream into an ethane containing stream to form a feed stream. The feed stream has at least 5 wt. % benzene based on the total weight of the feed stream. In addition, the process includes contacting the feed stream with an aromatization catalyst to produce an effluent stream comprising C7+ aromatic hydrocarbons. Less than 5 wt. % net benzene is produced during the contacting, based on a total weight of the feed stream.