C2-Rectifier and Splitter Layout for Higher Ethylene Capacity
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Solution Overview
Problem
The existing ethylene-ethane separation processes, particularly in C2-splitters, face limitations in capacity without compromising the quality of separation, necessitating an enhancement to increase efficiency.
Innovation Solution
The proposed solution involves installing a C2-rectifier and modifying the flow diagram to include an acetylene recovery or conversion unit, allowing for the separation of ethylene and ethane streams while maintaining high purity, and integrating the C2-rectifier overheads with the C2-splitter condensation system to increase capacity.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If the capacity of the C2-splitter is increased, then ethylene production capacity is improved, but the quality of separation may be compromised
Solution Approach 1:
The system is divided into two independent columns: a C2-rectifier column for producing high-purity ethylene and a C2-splitter column for separating ethylene and ethane. This segmentation allows each column to be optimized for its specific function, enabling increased overall capacity while maintaining separation quality through specialized design of each unit.
Solution Approach 2:
The C2-rectifier column acts as an intermediary unit between the feed source and the C2-splitter. It pre-processes the feed to remove lighter components and provide a optimized feed composition to the C2-splitter, thereby enhancing the splitter's capacity while maintaining its separation efficiency through improved feed conditions.
2Productivity
If a C2-rectifier is added to increase capacity, then ethylene production is improved, but device complexity increases
Solution Approach 1:
The overhead condenser of the C2-rectifier is integrated with the C2-splitter system, and the rectifier bottoms are fed to the splitter feed drum. This merging of functions and streams reduces the number of independent equipment items and simplifies the overall process configuration while still providing the capacity increase benefits of the additional column.
Solution Approach 2:
The C2-rectifier overhead condenser serves dual purposes: condensing rectifier overhead vapors and functioning as part of the C2-splitter condensation system. This multi-functionality reduces equipment count and simplifies the process while achieving the goal of increased ethylene production capacity.
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 results in a significant increase in ethylene production capacity, achieving at least 21.5% greater ethylene production with high purity separation, as demonstrated by simulation results.
Implementation Method 1
separating the C2-rich stream in a C2-rectifier to form a first ethylene stream and an ethane-rich bottoms stream
Implementation Method 2
integrating the C2-rectifier overheads with the C2-splitter condensation system
Data Source
AI summary
Processes to separate a light hydrocarbon stream comprising ethylene, ethane, and C3+ hydrocarbons into an ethylene stream, an ethane stream, and a C3+ hydrocarbon stream, including: feeding the light hydrocarbon stream to a deethanizer; separating the light hydrocarbons in the deethanizer to form a C3+ hydrocarbon bottoms stream and a C2-rich overhead stream comprising ethylene and ethane; separating the C2-rich stream in a C2-rectifier to form a first ethylene stream and an ethane-rich bottoms stream; and separating the ethane-rich bottoms stream in a C2-splitter to form a second ethylene stream and an ethane stream.