1,3-Butadiene Production via Integrated Dehydrogenation
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Solution Overview
Problem
Current methods for producing 1,3-butadiene, such as extractive distillation and dehydrogenation, face limitations due to the availability of C4 feedstock and high investment costs, with safety concerns and limited industrial applications, especially for small capacities.
Innovation Solution
A process that integrates a dehydrogenation section with existing or conventional plants for selective extraction of 1,3-butadiene from mixtures of saturated and unsaturated compounds, using a catalytic composition with microspheroidal alumina, Gallium, Tin, Platinum, and alkaline metals to maximize yield and reduce investment costs.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If extractive distillation is used for 1,3-butadiene production, then the process is simple and well-established, but the availability of C4 feedstock becomes increasingly limited
Solution Approach 1:
The patent combines extractive distillation and dehydrogenation processes into an integrated system where the extractive distillation unit processes C4 feedstock to separate 1,3-butadiene, while the dehydrogenation unit simultaneously converts butanes to butenes. The butenes from dehydrogenation are fed back to the extractive distillation unit, creating a merged process that overcomes feedstock limitations by generating additional C4 unsaturated compounds internally.
2Quantity of substance
If dehydrogenation technologies (Catadiene or Oxo-D) are used, then 1,3-butadiene can be produced from butanes, but the investment cost is significantly higher
Solution Approach 1:
Instead of implementing a full-scale standalone dehydrogenation plant which would be costly, the patent applies partial dehydrogenation action by integrating a dehydrogenation unit with the existing extractive distillation plant. The dehydrogenation unit processes only the raffinate stream from the extractive distillation, providing supplementary 1,3-butadiene production without the complete infrastructure and investment of a standalone dehydrogenation plant.
3Quantity of substance
If dehydrogenation technologies are implemented, then 1,3-butadiene production from butanes is enabled, but safety problems arise due to the nature of the process
Solution Approach 1:
The patent introduces an intermediary approach by using extractive distillation as the primary separation method and adding dehydrogenation as a supplementary process. The extractive distillation unit acts as a mediator that handles the bulk of 1,3-butadiene separation with well-established safety protocols, while the dehydrogenation unit processes only the raffinate stream under controlled conditions, minimizing safety risks associated with large-scale dehydrogenation operations.
4Productivity
If a standalone dehydrogenation plant is built, then 1,3-butadiene production is maximized, but the device complexity and investment cost increase significantly
Solution Approach 1:
The patent merges the extractive distillation plant and dehydrogenation unit into an integrated system where both processes work synergistically. The extractive distillation unit separates 1,3-butadiene from the C4 feedstock, while the dehydrogenation unit converts butanes in the raffinate stream to butenes, which are then fed back to the extractive distillation unit. This merging allows the system to achieve enhanced 1,3-butadiene production without the complexity of a standalone dehydrogenation plant.
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 process increases the recovery of 1,3-butadiene from traditional extraction plants, overcoming C4 fraction availability limitations without the need for a standalone dehydrogenation plant, offering economic convenience and improved safety, with a significant increase in production yield.
Implementation Method 1
A mixture of saturated and unsaturated compounds having from 2 to 10 carbon atoms in the chain, preferably a mixture of butanes and butenes, is fed to the extractive distillation section, from which a final product containing 1,3-butadiene and a raffinate product are obtained
Implementation Method 2
The raffinate product is subsequently fed to the catalytic dehydrogenation section to form a reaction effluent containing 1,3-butadiene and the saturated and unsaturated compounds having from 2 to 10 carbon atoms in the chain
Data Source
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AI summary
The present invention relates to a process for the production of 1, 3 -butadiene which comprises the following phases : a) extracting, by means of extractive distillation, in an extraction section, an end-product containing 1, 3 -butadiene and a raffinate product, starting from mixtures of saturated and unsaturated compounds having from 2 to 10 carbon atoms in the chain; b) sending the raffinate product to a dehydrogenation section; c) dehydrogenating the raffinate product in the dehydrogenation section in the presence of a dehydrogenation catalyst and an inert product so as to form a reaction effluent containing 1,3- butadiene; d) recirculating the reaction effluent containing 1, 3 -butadiene directly to the extraction section after separating the incondensable compounds.