Integrated 1,3-Butadiene Process Hydrating Ethylene By-products
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
The production of 1,3-butadiene from ethanol results in low selectivity and high formation of by-products, requiring complex separation and recycling processes, and existing hydration methods for ethylene face challenges with impurities and high operating costs.
Innovation Solution
Integrating a step for hydrating ethylene by-products with the 1,3-butadiene conversion process, allowing for shared separation and treatment stages, and using less pure ethylene, which is recycled back to the conversion process, along with co-produced water, to enhance overall yield and reduce operational costs and investments.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Object-generated harmful factors
If conventional separation and recycling processes are used to handle by-products, then by-product removal is achieved, but device complexity and operational costs increase
Solution Approach 1:
The patent combines the ethylene hydration process with the existing 1,3-butadiene production process by integrating the hydration reactor into the reaction sequence. The ethylene by-product from butadiene production is converted to ethanol in-situ, and the resulting stream is separated and recycled back to the butadiene reactor, eliminating the need for separate by-product handling systems.
Solution Approach 2:
The patent converts the harmful ethylene by-product (which requires separation and disposal) into a beneficial component (ethylene) that is transformed into ethanol through hydration. This ethanol then serves as feedstock for the butadiene production, turning a waste stream into a valuable resource that improves overall process efficiency.
2Productivity
If high purity ethylene is used for hydration, then hydration efficiency is improved, but separation and purification equipment requirements increase
Solution Approach 1:
The process uses its own by-products (ethylene and water from butadiene production) as feedstock for the hydration reaction. The ethylene is separated from the reaction mixture and directly fed to the hydration reactor without requiring external purification, as the process itself provides the necessary pure components through its separation units.
Solution Approach 2:
The separation units in the process serve multiple functions: they separate the main butadiene product, purify the ethylene by-product for hydration, and prepare the ethanol stream for recycling. This multi-functionality eliminates the need for dedicated purification equipment for the hydration process.
3Object-generated harmful factors
If dedicated catalytic units are used for by-product transformation, then by-product valorization is achieved, but device complexity and investment costs increase
Solution Approach 1:
The hydration reactor is integrated into the existing butadiene production train, sharing utilities, separation equipment, and recycle streams. The ethylene hydration process is combined with the butadiene synthesis process, allowing both reactions to occur in a coordinated manner within the same process framework.
Solution Approach 2:
The ethylene acts as an intermediary that connects the butadiene production and ethanol synthesis pathways. It is generated as a by-product in the butadiene reactor, converted to ethanol in the hydration reactor, and then recycled to the butadiene reactor, creating a closed-loop system that valorizes the by-product without requiring standalone treatment facilities.
Data Source
Figure 1
AI summary
The invention relates to a process for producing 1,3-butadiene from an ethanol-rich feedstock, i.e. in which the ethanol represents more than 50% of the total weight of said feedstock, comprising at least: A) a step of converting at least said ethanol-rich feedstock and the ethanol effluent resulting from the separation step B into a conversion effluent predominantly comprising 1,3-butadiene, water and ethylene, and into a hydrogen effluent, operating at a pressure between 0.1 and 1.0 MPa, at a temperature between 300°C and 500°C in the presence of at least one catalyst; B) a step of separating at least said conversion effluent resulting from A and the hydration effluent resulting from C into at least an ethanol effluent, a butadiene effluent, a water effluent and an ethylene effluent; C) an ethylene hydration step supplied at least by said ethylene effluent and/or said water effluent both resulting from the separation step B, in order to produce a hydration effluent comprising ethanol, said hydration effluent then being recycled to the separation step B.