Batch Olefin Isomerization with Heat Pump Integration
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Conventional processes for producing alpha olefins, such as hexene-1, are inefficient on a small scale due to the need for extensive energy and equipment to separate closely boiling double bond isomers, and they often require dedicated equipment for different carbon number streams, leading to high capital and utility costs.
Innovation Solution
A batch process utilizing a single isomerization reactor and superfractionator system that operates in campaign mode, allowing for sequential processing of C4 and C6 hydrocarbons, with a heat pump for heat integration and shared equipment usage to reduce costs and energy consumption.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If conventional continuous processes with dedicated equipment for different carbon number streams are used, then production reliability is improved, but capital costs and device complexity increase significantly
Solution Approach 1:
The fractionator is designed to handle multiple carbon number streams (C4 and C6) sequentially through batch operation. The same equipment performs different separation functions at different times, eliminating the need for dedicated fractionators for each carbon number stream while maintaining separation reliability
Solution Approach 2:
The process operates in sequential batches, alternating between processing C4 streams and C6 streams. The fractionator is prepared for a specific carbon number stream, processes it to completion, then is reconfigured for the next stream type. This periodic operation allows one piece of equipment to replace what would traditionally require multiple continuous units
2Manufacturing precision
If extensive separation equipment is used to separate closely boiling double bond isomers, then manufacturing precision is improved, but energy consumption increases
Solution Approach 1:
Isomerization reactions are performed before fractionation to convert double bond isomers into more separable configurations. By preliminarily altering the molecular structure through isomerization, the subsequent separation becomes more efficient and requires less energy-intensive fractionation
Solution Approach 2:
The process utilizes temperature and pressure parameter changes during batch fractionation to optimize separation of closely boiling isomers. By dynamically adjusting operating parameters rather than relying on fixed continuous operation, the system achieves high separation precision with reduced energy consumption
3Reliability
If dedicated equipment for different carbon number streams is implemented, then production reliability is improved, but capital costs increase by 35-45%
Solution Approach 1:
Key equipment including the fractionator, isomerization reactor, and heat pump are designed to handle multiple carbon number streams sequentially. This multi-functionality reduces the total number of equipment items needed, directly lowering capital costs while maintaining production reliability through proven batch operation procedures
Solution Approach 2:
The process merges the handling of C4 and C6 streams into a single integrated batch system. Equipment that would traditionally be separate for different stream types is combined and shared through sequential operation, reducing overall plant capital requirements by 35-45%
4Ease of manufacture
If batch process with shared equipment is used, then capital costs are reduced by 35-45%, but operational complexity increases
Solution Approach 1:
The batch process follows a periodic cycle of preparing equipment for a specific carbon number stream, processing it to completion, then transitioning to the next stream type. This structured periodic operation, while requiring coordination, simplifies operational complexity compared to managing multiple continuous streams by concentrating control activities in discrete phases
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 approach reduces capital costs by 35-45% and lowers utility expenses by enabling efficient production of alpha olefins across different carbon numbers with improved energy efficiency, making it suitable for smaller capacity installations.
Implementation Method 1
isomerizing the feed stream in a first isomerization reactor to increase the quantity of the alpha olefin having the first carbon number
Implementation Method 2
fractionating the first isomerization effluent in a first fractionator to obtain a bottoms stream comprising the internal olefin having the first carbon number and an overhead stream comprising the alpha olefin having the first carbon number
Implementation Method 3
subjecting the overhead stream to catalytic metathesis in a metathesis reactor under conditions and in the presence of a first metathesis catalyst to produce a mixed olefin effluent comprising an internal olefin having a second carbon number
Implementation Method 4
with a heat pump for heat integration
Data Source
AI summary
Disclosed herein is a process for producing an alpha olefin comprising obtaining a feed stream comprising an internal olefin having a first carbon number and an alpha olefin having a first carbon number, isomerizing the feed stream to increase the quantity of the alpha olefin, fractionating, subjecting the overhead material from fractionation to catalytic metathesis to produce a mixed olefin effluent comprising an internal olefin having a second carbon number and other hydrocarbons, fractionating, preparing the first isomerization reactor and fractionator to receive the olefin having a second carbon number, isomerizing the internal olefin intermediate in the prepared first isomerization reactor, and fractionating the second isomerization effluent in the prepared first fractionator to separate the alpha olefin having the second carbon number from the internal olefin having the second carbon number. A corresponding system also is disclosed, along with a heat pump that can be incorporated into the process.