Ethanol to 1,3-Butadiene Yield via Molar Ratio Control
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Solution Overview
Problem
Conventional methods for producing 1,3-butadiene have limitations in yield, necessitating an improvement in the continuous production process.
Innovation Solution
A method involving a multi-step process including gas preparation, conversion, and purification of 1,3-butadiene from an ethanol feedstock, utilizing parallel reactors and catalyst regeneration to optimize ethanol/acetaldehyde molar ratios and separate hydrogen, butene, and acetaldehyde, enhancing yield through controlled temperature and pressure conditions.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If conventional production methods are used, then the process is simple, but the yield of 1,3-butadiene is low
Solution Approach 1:
The production process is divided into multiple sequential steps: gas preparation step (vaporizing ethanol feedstock), conversion step (converting ethanol to 1,3-butadiene in presence of catalyst), and purification step (separating 1,3-butadiene from crude gas). This segmentation allows each step to be optimized independently, improving overall yield while managing complexity through structured process design
Solution Approach 2:
The gas preparation step vaporizes the ethanol feedstock before the conversion step, preparing the reactants in advance in the optimal state for catalytic conversion. This preliminary action ensures that ethanol is in the correct phase and concentration range for high-yield conversion to 1,3-butadiene
2Productivity
If ethanol/acetaldehyde molar ratio is not controlled, then the process is easier to operate, but the yield of 1,3-butadiene decreases
Solution Approach 1:
The ethanol/acetaldehyde molar ratio in the intermediate gas is monitored and controlled by mixing with acetaldehyde-containing gas from the purification step. This feedback mechanism ensures the ratio remains within the optimal range of 1 to 100, maintaining high yield while providing a clear control parameter for operation
Solution Approach 2:
The process controls the ethanol/acetaldehyde molar ratio as a key parameter within the range of 1 to 100. By maintaining this specific parameter range through controlled mixing, the conversion efficiency to 1,3-butadiene is maximized, transforming a quality attribute into a controllable process parameter
3Manufacturing precision
If purification steps are simplified, then the process is shorter, but the purity of 1,3-butadiene decreases
Solution Approach 1:
The purification step is segmented into multiple separation operations: gas-liquid separation to remove hydrogen, distillation to separate ethylene and acetaldehyde, and final purification. Each segmentation targets specific impurities, achieving high purity through cumulative effect while keeping each individual step relatively simple
Solution Approach 2:
Acetaldehyde-containing gas from the purification step is used as an intermediary to adjust the ethanol/acetaldehyde ratio in the conversion step. This intermediary serves dual purposes: it purifies the 1,3-butadiene stream while simultaneously optimizing the feed composition for the conversion reactor
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 enables continuous high-yield production of 1,3-butadiene, improving the efficiency and purity of the product by adjusting ethanol/acetaldehyde ratios and regenerating catalysts, thus addressing the yield limitations of conventional methods.
Implementation Method 1
converting ethanol into acetaldehyde in the presence of a first catalyst under a pressure of 0 to 1.0 MPaG and at a temperature of 50 to 500° C.
Implementation Method 2
converting the intermediate gas into 1,3-butadiene under a pressure of 0 to 1.0 MPaG and at a temperature of 50 to 500° C. in the presence of a second catalyst
Implementation Method 3
separating hydrogen gas from the crude gas by gas-liquid separation to obtain a 1,3-butadiene-containing liquid
Implementation Method 4
distilling a liquefied product of the crude gas or the 1,3-butadiene-containing liquid to separate the liquefied product or the 1,3-butadiene-containing liquid into an ethylene-containing gas, a 1,3-butadiene-containing effluent, and an acetaldehyde-containing liquid
Implementation Method 5
vaporizing the ethanol feedstock to obtain the ethanol-containing gas under a pressure of −1.0 to 1.0 MPaG and at a temperature of −100 to 200° C.
Implementation Method 6
converting butene in the crude gas into 1,3-butadiene by dehydrogenation reaction
Data Source
AI summary
In the method of the present invention, 1,3-butadiene is produced by vaporizing an ethanol feedstock in a vaporizer (104), feeding the resulting into two or more parallel first reactors (108) to convert the ethanol to acetaldehyde in the presence of a first catalyst, supplying the resulting intermediate gas to a second reactor (110) to convert the ethanol and acetaldehyde to 1,3-butadiene in the presence of a second catalyst, purifying the resulting crude gas containing 1,3-butadiene by a gas-liquid separator (112), a first distillation column (114), a fourth reactor (116), a second distillation column (118), and mixing one of both of a part of the ethanol-containing gas and an acetaldehyde-containing gas obtained in the second distillation column (118) are mixed with the intermediate gas, thereby adjusting an ethanol/acetaldehyde molar ratio in the intermediate gas to 1 to 100.