Ethylene Oligomerization Dispersion Recirculation Loop
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Solution Overview
Problem
Existing oligomerization processes using gas/liquid reactors face significant losses of unreacted ethylene in the gas headspace, leading to reduced yield and increased costs due to inefficient management of the gas phase, particularly in bubble-point reactors with recirculation loops.
Innovation Solution
The process involves dispersing the ethylene from the gas headspace into the liquid fraction within the recirculation loop, increasing the contact surface area between the liquid and gas phases, thereby enhancing ethylene dissolution and conversion in the oligomerization reaction.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If the gas headspace is bled to eliminate gaseous compounds, then the gas phase is purged of non-condensable gases, but unreacted ethylene is lost significantly
Solution Approach 1:
The invention changes the pressure parameter by operating at elevated pressures (10-300 atm) to increase ethylene solubility in the liquid phase. This parameter change allows the gas headspace to be bled for removing non-condensable gases while minimizing ethylene loss, as the high pressure keeps ethylene dissolved in the liquid rather than allowing it to escape with the gas bleed
Solution Approach 2:
The invention uses a composite catalytic system comprising multiple catalysts (e.g., TiCl4 with AlEt3, or combinations of different metal catalysts) that work synergistically to enhance ethylene conversion efficiency. This composite catalytic approach improves the utilization of ethylene that does dissolve, thereby reducing overall ethylene loss
2Productivity
If ethylene is introduced into the reaction chamber for oligomerization, then the desired linear alpha-olefins are produced, but unreacted ethylene accumulates in the gas headspace
Solution Approach 1:
The invention changes the pressure parameter by operating at elevated pressures (10-300 atm) to increase ethylene solubility in the liquid phase. This ensures that more ethylene remains dissolved and available for reaction rather than accumulating in the gas headspace, thereby improving both productivity and ethylene utilization
Solution Approach 2:
The invention implements a recirculation system where liquid phase is continuously circulated through a heat exchanger and back into the reaction chamber. This continuous circulation maintains constant contact between dissolved ethylene and the catalytic system, ensuring continuous conversion and preventing ethylene accumulation in the gas phase
3Stability of the object's composition
If a recirculation loop is used to control temperature and homogeneity, then reaction conditions are stabilized, but ethylene dissolution efficiency is reduced
Solution Approach 1:
The invention changes the pressure parameter to high levels (10-300 atm) to overcome the negative effect of recirculation on ethylene dissolution. The elevated pressure maintains high ethylene solubility even during recirculation, ensuring that ethylene dissolution efficiency is not compromised while still benefiting from the temperature and composition stability provided by recirculation
Solution Approach 2:
The invention introduces ethylene into the liquid phase before the recirculation process begins, allowing ethylene to dissolve under high pressure conditions. This preliminary dissolution action ensures that ethylene is already in solution before recirculation starts, preventing loss of dissolution efficiency while maintaining the stabilizing benefits of recirculation
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 optimizes ethylene conversion and reduces costs by minimizing ethylene loss, improving the productivity of the oligomerization process and enhancing the yield of linear alpha-olefins such as 1-butene, 1-hexene, or 1-octene.
Implementation Method 1
The invention consists in consisting in dispersing the liquid fraction introduced at the top of the reaction chamber in the gas phase present in the upper part of the reaction chamber, in order to increase the surface area of contact between the dispersed liquid and the ethylene present in the gas phase, and thus to increase the amount of ethylene dissolved in the dispersed liquid fraction
Data Source
AI summary
The present invention relates to an oligomerization process using a reaction device comprising a dispersion means. In particular, the process relates to the oligomerization of ethylene to give linear α-olefins, such as 1-butene, 1-hexene or 1-octene, or a mixture of linear alpha-olefins.