Alpha-Olefin Production Flasher Scrubber Impurity Removal
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Solution Overview
Problem
The continuous production of α-olefin is hindered by clogging in pipelines and compressors due to impurities in the gas component obtained from the polymerization-reaction solution, which contains components other than ethylene, such as catalysts, leading to difficulties in long-term operation.
Innovation Solution
A method involving the separation of the reaction mixture in a flasher with a specific separation drop size and subsequent contact with a solvent in a scrubber to remove impurities, allowing for the reuse of unreacted ethylene in the polymerization reaction, using a plate or bubble tower type scrubber and potentially multiple flashers to enhance efficiency.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Loss of energy
If unreacted ethylene is recovered from polymerization-reaction solution using a flasher and reused, then the consumption rate of starting material is reduced, but clogging occurs in pipe lines and compressors due to impurities such as catalyst
Solution Approach 1:
The gas component separation process is divided into multiple stages using multiple flashers with different separation drop sizes. The first flasher performs initial separation, and subsequent flashers perform further separation, progressively removing impurities like catalyst from the gas stream before ethylene reuse, thereby preventing clogging while maintaining recovery efficiency.
Solution Approach 2:
Different flashers are designed with specific separation drop sizes tailored to their position in the process sequence. The first flasher has one separation drop size for initial separation, while subsequent flashers have different separation drop sizes optimized for removing specific impurities at different stages, allowing targeted removal of harmful components.
2Productivity
If continuous production of α-olefin is performed, then productivity is improved, but clogging by impurities prevents long-term continuous operation
Solution Approach 1:
Impurities such as catalyst are removed from the gas component in advance through multiple flasher stages before the gas is reused in the polymerization reaction. This preliminary removal of harmful substances prevents subsequent clogging issues, enabling long-term continuous operation without interruptions for maintenance.
Solution Approach 2:
The multiple flasher system is designed to operate continuously, with each flasher stage continuously separating and removing impurities from the gas stream. This continuous purification process ensures that the reused ethylene remains clean throughout extended operation periods, maintaining both productivity and reliability over the long term.
3Quantity of substance
If gas component is separated using a flasher, then unreacted ethylene is recovered, but impurities such as catalyst remain in the gas component
Solution Approach 1:
The gas purification process is segmented into multiple flasher stages, each performing a portion of the separation task. The first flasher recovers ethylene and removes some impurities, while subsequent flashers further purify the gas by removing remaining impurities like catalyst, achieving both high recovery and high purity through divided processing steps.
Solution Approach 2:
Multiple flashers act as intermediary separation stages between the initial gas separation and the final ethylene reuse. Each flasher serves as an intermediate step that progressively purifies the gas component, with the series of flashers collectively achieving the required purity level while maintaining efficient ethylene recovery.
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
This method reduces clogging and enables continuous long-term operation by effectively separating and removing impurities, ensuring efficient recovery and reuse of ethylene, thereby improving production efficiency.
Implementation Method 1
a step of continuously separating the reaction mixture into a gas A and a liquid B in a flasher having a separation drop size di represented by the formula (1) below of 1.0×10−4 m or less: in which v represents a rising speed (m/s) of a gas in the flasher, ρV represents a density (kg/m3) of the gas A, ρL represents a density (kg/m3) of the liquid B, g represents the gravitational acceleration (m/s2)
Implementation Method 2
a step of bringing the gas A into contact with a solvent in a scrubber to obtain a gas C containing an unreacted ethylene and a liquid D containing the solvent
Data Source
AI summary
A method may produce an α-olefin and may include: (1) continuously introducing an ethylene and a catalyst into a reactor, then mixing and polymerizing to obtain a reaction mixture; (2) continuously separating the reaction mixture into a gas A and a liquid B in a flasher having a separation drop size d of formula (1) of 1.0×10−4 m or less:dL=18μvg(ρL-ρV),(1)v being rising speed (m/s) of a gas in the flasher, ρV being density (kg/m3) of the gas A, ρL being density (kg/m3) of the liquid B, g being gravitational acceleration (m/s2), and u being viscosity (Pa·s) of the gas A; (3) bringing the gas A into contact with a solvent in a scrubber to obtain a gas C containing an unreacted ethylene and a liquid D containing the solvent; and (4) reusing the gas C in a polymerization.