Ethane to Ethylene and Carbon Monoxide via CO2 Conversion
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Solution Overview
Problem
Current processes for producing ethylene and carbon monoxide mixtures are costly due to reliance on conventional sources like steam cracking and methane steam reforming, making ethylene an expensive starting material, while ethane, a component of natural gas, is more economically viable.
Innovation Solution
A process involving contacting ethane and carbon dioxide at temperatures of at least 500°C to produce ethylene and carbon monoxide, followed by using these products with an ethylene carbonylation catalyst to form alkyl propionate, and further processing to create methacrylic acid esters or copolymers.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Quantity of substance
If conventional sources (steam cracking, methane steam reforming) are used to produce ethylene, then ethylene can be produced, but the production cost is high
Solution Approach 1:
The patent changes the starting material from conventional ethylene sources to ethane, and modifies the reaction conditions by using high temperature (500-1000°C) and specific catalysts to achieve cost-effective production of ethylene and carbon monoxide mixtures
Solution Approach 2:
The patent uses ethane, which is cheaper and more abundant than conventional ethylene sources, as the starting material to produce the required chemical feedstock at lower cost
2Ease of manufacture
If ethane is used as a starting material instead of ethylene, then production cost is reduced, but the process complexity increases
Solution Approach 1:
The patent combines multiple functions into a single integrated process: the catalytic conversion of ethane and carbon dioxide produces both ethylene and carbon monoxide in one step, which are then used as feedstock for subsequent carbonylation reactions, eliminating the need for separate production steps
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 method provides a cost-effective alternative for producing ethylene and carbon monoxide mixtures, enabling the production of valuable chemicals like alkyl propionates and methacrylic acid esters using abundant ethane as a starting material, reducing production costs and increasing efficiency.
Implementation Method 1
contacting ethane and carbon dioxide at a temperature of at least 500° C. to produce ethylene and carbon monoxide
Implementation Method 2
contacting an alcohol, and the ethylene and carbon monoxide with an ethylene carbonylation catalyst to produce an alkyl propionate
Data Source
AI summary
A method for producing a mixture of ethylene and carbon monoxide by contacting ethane and an oxygen source at a temperature of at least 500° C. to produce ethylene and carbon monoxide. A method for producing an alkyl propionate by steps of: (a) contacting ethane and an oxygen source at a temperature of at least 500° C. to produce ethylene; (b) contacting an alcohol, ethylene and carbon monoxide with an ethylene carbonylation catalyst to produce the alkyl propionate; and (c) separating the alkyl propionate from byproducts and starting materials. The method further comprises condensing the alkyl propionate with formaldehyde to produce an alkyl methacrylate.