C5 Fraction Separation for Hydrocarbon Resin Production
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Solution Overview
Problem
Current processes for isolating valuable components like cis and trans 1,3 pentadienes and dicyclopentadiene from pyrolysis gasoline in ethylene production units result in the loss of key reactive monomers and diolefins, as they are either destroyed or rejected during isoprene purification, limiting the production of hydrocarbon resins and increasing energy and capital costs.
Innovation Solution
A system comprising multiple dimer reactor systems, distillation columns, and extractive distillation units is designed to recover DCPD and piperylene streams, allowing for the production of hydrocarbon resin grade streams while minimizing isoprene loss and reducing the number of recycle streams, thereby enhancing the value of byproducts and operating efficiency.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Quantity of substance
If traditional isoprene purification processes are used, then isoprene recovery is maximized, but key reactive monomers and diolefins are lost or destroyed
Solution Approach 1:
The C5 fraction separation process is divided into multiple sequential distillation columns (deisopentanizer, C5 splitter, Pips column, DCPD column) to separately isolate different components. This segmentation allows isoprene to be purified while directing DCPD and piperylene streams to different destinations, preventing loss of valuable reactive monomers and diolefins.
Solution Approach 2:
Different quality standards and processing paths are applied to different components within the C5 fraction. Isoprene undergoes traditional purification, while DCPD and piperylene streams are directed to hydrocarbon resin production units where their reactive properties are utilized as feedstocks rather than being destroyed through hydrogenation.
2Manufacturing precision
If traditional C5 separation design is used, then isoprene purification is achieved, but DCPD and 1,3 pentadienes are rejected or lost
Solution Approach 1:
Instead of discarding DCPD and 1,3 pentadienes as waste streams requiring hydrogenation, the process recovers them as valuable feedstocks for hydrocarbon resin production. The DCPD column specifically isolates DCPD for resin manufacturing, while the Pips column recovers 1,3 pentadienes, transforming waste into valuable resources.
3Manufacturing precision
If hydrogenation is applied to remove alkynes, then stream quality is upgraded, but energy and capital costs increase
Solution Approach 1:
Alkynes are extracted and removed as a separate stream through the distillation sequence rather than being treated with hydrogenation. The deisopentanizer and subsequent columns separate alkynes into a distinct fraction that can be handled independently, eliminating the need for expensive hydrogenation units while maintaining stream quality.
4Manufacturing precision
If multiple purification columns and water wash towers are used, then isoprene purity is achieved, but device complexity increases
Solution Approach 1:
The distillation columns serve multiple functions simultaneously. For example, the C5 splitter not only separates isoprene from heavier components but also begins the concentration of DCPD and piperylene streams. The deisopentanizer removes both light ends and prepares the feed for subsequent separation stages, reducing the need for dedicated units for each function.
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
The system efficiently produces hydrocarbon resin grade DCPD and piperylene streams, increasing the value of byproducts and reducing capital and energy costs by minimizing isoprene loss and the number of recycle streams, while maintaining the quality of isoprene and hydrocarbon resin production.
Implementation Method 1
The art of separation has been well known for many decades and uses equipment such as dimer reactors, distillation columns, and extractive distillation methods
Implementation Method 2
a sequence of minimum of two dimer reactor systems, with each system having more than one dimer drum in parallel arrangement
Implementation Method 3
heat exchangers in front of dimer systems
Data Source
AI summary
Apparatuses, systems and methods for producing Pips stream for manufacturing catalytic C5 hydrocarbon resins containing all the key reactive monomers that are already present in the C5 fraction of the pyrolysis gasoline, which is otherwise lost with the crude isoprene stream, are disclosed herein. Embodiments of the invention are directed to producing a hydrocarbon resin grade DCPD stream consisting of dimers and codimers of isoprene which are of value in manufacturing thermal hydrocarbon resins, either polymer grade isoprene and gasoline quality raffinate (free or sulfur and acetylenes) or a relatively small crude isoprene stream with maximum utilization of isoprene by moving some of the isoprene to a DCPD stream used to manufacture thermal hydrocarbon resins.