Ethane ODH Reactor Cooling Sections for Higher Ethylene Selectivity
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Solution Overview
Problem
Existing oxidative dehydrogenation (ODH) reactor systems for ethylene production face high energy consumption due to the need for significant amounts of dilution steam, which is inefficient and contributes to carbon dioxide emissions, while also leading to unwanted formation of carbon monoxide and carbon dioxide, reducing ethylene yield.
Innovation Solution
The ODH reactor system reduces dilution steam by optimizing the feed composition and reactor configuration, including lower oxygen levels, improved heat transfer, and multi-reactor setups, with coolant circulation to maintain optimal temperatures and minimize unwanted reactions, thereby increasing ethylene selectivity and reducing energy consumption.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Temperature
If significant amounts of dilution steam are used in ODH reactor systems, then the reactor can operate and manage heat, but energy consumption increases and carbon dioxide emissions increase
Solution Approach 1:
The patent changes the chemical composition parameters of the diluent from steam to nitrogen or carbon dioxide. This parameter change allows the reactor to maintain temperature control while reducing energy consumption and carbon dioxide emissions, as nitrogen and carbon dioxide do not require the same energy input for vaporization and do not contribute to CO2 emissions in the same way steam does.
Solution Approach 2:
The patent employs an inert atmosphere by using nitrogen or carbon dioxide as diluents instead of steam. These inert gases create a non-flammable environment that allows safe operation while reducing energy consumption and carbon dioxide emissions, as they do not require the high energy input needed for steam vaporization and do not contribute to CO2 emissions.
2Temperature
If significant amounts of dilution steam are used in ODH reactor systems, then the reactor can operate and manage heat, but carbon dioxide emissions increase
Solution Approach 1:
The patent changes the chemical composition parameters of the diluent from steam to nitrogen or carbon dioxide. This parameter change allows the reactor to maintain temperature control while reducing carbon dioxide emissions, as nitrogen and carbon dioxide do not contribute to CO2 emissions in the same way steam does.
Solution Approach 2:
The patent employs an inert atmosphere by using nitrogen or carbon dioxide as diluents instead of steam. These inert gases create a non-flammable environment that allows safe operation while reducing carbon dioxide emissions, as they do not require the high energy input needed for steam vaporization and do not contribute to CO2 emissions.
3Productivity
If conventional ODH reactor configuration is used, then the reactor can process ethane, but unwanted formation of carbon monoxide and carbon dioxide reduces ethylene yield
Solution Approach 1:
The patent applies local quality by implementing multiple cooling sections with different temperature profiles along the reactor length. The first cooling section maintains a lower temperature to suppress unwanted reactions, while subsequent sections allow higher temperatures for optimal ethylene formation. This localized temperature control improves ethylene yield while minimizing carbon monoxide and carbon dioxide formation.
Solution Approach 2:
The patent segments the reactor into multiple cooling sections, each with independent temperature control. This segmentation allows different regions of the reactor to operate at different temperatures, optimizing ethylene production while suppressing unwanted reactions that produce carbon monoxide and carbon dioxide in specific zones.
4Productivity
If multi-reactor setup with oxygen injection is used, then ethylene production efficiency improves, but device complexity increases
Solution Approach 1:
The patent merges multiple reactor units into a single integrated system with shared cooling and injection systems. By combining the functions of multiple reactors while maintaining their series configuration, the system achieves improved ethylene production efficiency without proportionally increasing device complexity, as the cooling and oxygen injection systems are shared across all reactor units.
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 decreases energy consumption, minimizes carbon dioxide emissions, and enhances ethylene yield by favoring ethylene formation over carbon monoxide and carbon dioxide, thus improving the overall efficiency and environmental footprint of the ODH plant.
Implementation Method 1
Ethane is converted into ethylene via ODH catalyst on the tube side
Implementation Method 2
catalyst for the conversion of an alkane to a corresponding alkene
Implementation Method 3
Coolant is routed through the shell side of the ODH reactor to maintain the tube side at a first temperature
Data Source
AI summary
An oxidative dehydrogenation (ODH) reactor system and a method of operating the ODH reactor system, including providing feed having ethane, oxygen, and diluent to give a reaction mixture flowing through the tube side of the ODH reactor, and converting ethane into ethylene with ODH catalyst on the tube side. Coolant is routed through the shell side of the ODH reactor to maintain the tube side at a first temperature in a first cooling section and at a second temperature in a second cooling section, wherein the first temperature is lower than the second temperature. The ODH reactor system may include more than one ODH reactor. For ODH reactor systems having more than one ODH reactor is series, oxygen gas may be injected between ODH reactors.