CO Oxidation Reactor for Acetylene Converter Feed Control
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Solution Overview
Problem
Industrial processes for producing ethylene face challenges in controlling carbon monoxide (CO) concentrations in ethylene-rich streams, as excessive CO can attenuate the activity of acetylene selective hydrogenation catalysts, leading to suboptimal acetylene conversion and reduced catalyst operational windows.
Innovation Solution
A system comprising a CO oxidation reactor placed downstream of a treatment unit that removes hydrogen sulfide (H2S) and optionally CO2, followed by a second unit to remove CO2, to convert CO to CO2, thereby controlling CO concentrations before acetylene selective hydrogenation, using elemental oxygen as an oxidant and suitable catalysts like ruthenium on alumina.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If CO concentration is high in the ethylene rich stream, then the acetylene selective hydrogenation catalyst activity is attenuated, but removing CO requires additional treatment units
Solution Approach 1:
The CO oxidation reactor is positioned upstream of the acetylene selective hydrogenation unit to preliminarily remove CO from the ethylene rich stream before it reaches the hydrogenation catalyst. This preliminary action prevents CO from attenuating catalyst activity, ensuring reliable hydrogenation performance without requiring complex downstream adjustments or additional treatment stages.
2Quantity of substance
If CO is removed by oxidation to CO2, then CO concentration is reduced, but CO2 removal requires additional treatment steps
Solution Approach 1:
The process converts the harmful CO into CO2 through oxidation in the CO oxidation reactor. Although CO2 is also a contaminant requiring removal, this conversion is beneficial because CO2 is easier to remove than CO, and the subsequent CO2 removal can be integrated with existing amine treatment units already present in the ethylene purification train, minimizing additional complexity.
3Manufacturing precision
If multiple treatment units are added for CO control, then CO concentration is controlled, but process complexity increases
Solution Approach 1:
The CO oxidation reactor is designed to work seamlessly with existing amine treatment units in the ethylene purification process. The oxidation unit converts CO to CO2, and the subsequent CO2 removal utilizes the same amine-based absorption technology already employed for H2S and CO2 removal elsewhere in the process, making the CO control function universal and integrated rather than requiring entirely separate specialized equipment.
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 effectively reduces CO concentrations to a suitable range for stable and efficient acetylene conversion, extending catalyst operational windows and maintaining high purity ethylene production.
Implementation Method 1
a CO oxidation reactor to convert CO to CO2 and forming a CO-depleted gas stream
Implementation Method 2
a first treatment unit for removing H2S and, optionally, CO2 from the gas stream
Implementation Method 3
an acetylene selective hydrogenation downstream of the CO oxidation reactor
Data Source
AI summary
A system and process for acetylene selective hydrogenation of an ethylene rich gas stream. An ethylene rich gas supply comprising at least H2S, CO2, CO, and acetylene is directed to a first treatment unit for removing H2S and optionally CO2 from the gas stream. A CO oxidation reactor is used to convert CO to CO2 and form a CO-depleted gas stream. A second treatment unit removes the CO2 from the CO-depleted gas stream and an acetylene selective hydrogenation treats the CO-depleted gas stream.