Ethanol Production via Dimethyl Ether Recycle
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Solution Overview
Problem
Existing processes for converting methane to ethanol and/or ethylene suffer from low yields, require expensive oxygen generation, and produce significant undesirable by-products, with syngas-based schemes often needing additional co-feeds and resulting in substantial by-product formation.
Innovation Solution
A process involving a feed mixture of carbon monoxide, hydrogen, and dimethyl ether, converted in the presence of a multi-component catalyst system to produce ethanol, with methanol coproduced and subsequently dehydrated to recycle dimethyl ether, minimizing by-product production and requiring only a syngas feed.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If methane is converted directly to ethylene via oxidative coupling, then ethylene production is achieved, but yields are low and carbon oxides are produced
Solution Approach 1:
The patent introduces dimethyl ether as an intermediary substance that mediates the conversion process. Instead of directly converting methane to ethylene, the process converts methane to dimethyl ether first, then to ethanol, and finally to ethylene. This intermediary approach allows for better control of the reaction pathway, reducing carbon oxide formation while maintaining ethylene production efficiency.
Solution Approach 2:
The patent changes the chemical parameters of the process by using dimethyl ether as a carrier and intermediate. The process operates at controlled temperatures and pressures where dimethyl ether can be formed from methane, then converted to ethanol through hydrogenation, and finally dehydrated to ethylene. This parameter control enables higher yields with reduced harmful by-products.
2Productivity
If syngas is converted to ethanol through conventional routes, then ethanol production is achieved, but methanol and propylene by-products are formed
Solution Approach 1:
The patent extracts and removes methanol from the reaction mixture by using it as a reactant in the formation of dimethyl ether. Instead of allowing methanol to remain as a by-product, the process consumes it to form dimethyl ether, which then enters the hydrogenation step to produce ethanol. This extraction approach eliminates methanol by-products while maintaining ethanol production.
Solution Approach 2:
The patent implements a feedback mechanism where methanol produced in the initial step is fed back into the system to form dimethyl ether, which then participates in the hydrogenation reaction. This feedback loop ensures that methanol is not wasted but is instead utilized to produce additional ethanol, improving overall yield while preventing methanol accumulation as a harmful by-product.
3Productivity
If methanol is dehydrated to produce dimethyl ether, then process efficiency is improved, but additional energy input is required
Solution Approach 1:
The patent creates a continuous cycle where methanol is dehydrated to dimethyl ether, which then undergoes hydrogenation to form ethanol. The ethanol can be further dehydrated to ethylene. This continuous action ensures that no valuable chemicals are wasted, and the energy input for dehydration is offset by the value of the products formed. The process maintains continuous useful action throughout the reaction sequence.
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 process efficiently produces ethanol with reduced by-product formation, specifically minimizing methanol and propylene production, and allows for the optional conversion of ethanol to ethylene or butadiene, utilizing a single catalyst system and recycling dimethyl ether to maintain process efficiency.
Implementation Method 1
converted in the presence of a multi-component catalyst system to produce ethanol
Implementation Method 2
methanol coproduced and subsequently dehydrated to recycle dimethyl ether
Implementation Method 3
at least part of the carbon monoxide in the feed reacts with at least part of the dimethyl ether in the feed to produce methyl acetate
Implementation Method 4
at least part of the hydrogen in the feed reacts with at least part of the methyl acetate produced in (ii) to produce methanol and ethanol
Data Source
AI summary
This invention relates to a process for producing ethanol comprises supplying a feed comprising carbon monoxide, hydrogen and dimethyl ether to a reaction zone operated under conditions such that (i) part of the carbon monoxide in the feed reacts with part of the hydrogen in the feed to produce methanol; (ii) part of the carbon monoxide in the feed reacts with at least part of the dimethyl ether in the feed to produce methyl acetate; and (iii) part of the hydrogen in the feed reacts with at least part of the methyl acetate produced in (ii) to produce an effluent comprising methanol and ethanol. At least part of the ethanol is recovered from the effluent and at least part of the methanol is dehydrated to produce dimethyl ether, which is recycled to the reaction zone.