Ethylene Oxide Production via Ethane Ballast Integration
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Solution Overview
Problem
Current processes for producing ethylene oxide are cumbersome and costly due to the need for large ethylene/ethane splitters and additional ballast gases, as the separation of ethane from ethylene requires high energy input and complex equipment, and the use of nitrogen or methane as ballast gases is inefficient.
Innovation Solution
An integrated process where ethylene and ethane are subjected to oxidation conditions, separating the stream into two compositions before oxidation, allowing ethane to function as a ballast gas and reducing the need for additional ballast gases, and recycling unconverted ethylene and ethane for further processing, thereby simplifying the separation process and reducing energy costs.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If a large ethylene/ethane splitter is used to completely separate ethane from ethylene, then the purity of ethylene is improved, but the device complexity and energy consumption increase significantly
Solution Approach 1:
The patent extracts only the necessary portion of ethane removal - instead of completely separating ethane from ethylene, the process removes only sufficient ethane to enable safe oxidation, leaving some ethane in the feed. This eliminates the need for large complex splitters while achieving the required ethylene purity for oxidation.
Solution Approach 2:
The patent applies partial action by not completely removing ethane but rather achieving partial removal sufficient for oxidation safety. The ethylene stream is freed from excessive ethane content that would interfere with oxidation, while accepting some residual ethane presence, thus avoiding the complexity of complete separation.
2Manufacturing precision
If a large ethylene/ethane splitter is used to completely separate ethane from ethylene, then the purity of ethylene is improved, but the energy consumption increases significantly
Solution Approach 1:
The patent extracts only the necessary portion of ethane removal - instead of completely separating ethane from ethylene, the process removes only sufficient ethane to enable safe oxidation, leaving some ethane in the feed. This eliminates the need for large complex splitters while achieving the required ethylene purity for oxidation.
Solution Approach 2:
The patent applies partial action by not completely removing ethane but rather achieving partial removal sufficient for oxidation safety. The ethylene stream is freed from excessive ethane content that would interfere with oxidation, while accepting some residual ethane presence, thus avoiding the complexity of complete separation.
3Reliability
If nitrogen or methane is added as ballast gas for safe operability in ethylene oxidation, then the safety is improved, but the process complexity and cost increase
Solution Approach 1:
The patent applies self-service by using the ethane already present in the ethylene stream as the ballast gas for safe oxidation. Instead of adding external ballast gases like nitrogen or methane, the process utilizes the inherent ethane content to control safe operability, eliminating the need for additional ballast gas addition systems.
Solution Approach 2:
The patent applies multi-functionality to ethane, which serves dual purposes: (1) as an unreacted component from the ethylene production process, and (2) as the ballast gas ensuring safe operability during oxidation. This eliminates the need for separate ballast gas systems and reduces process complexity.
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 reduces the complexity and energy expenditure of ethylene oxide production by allowing ethane to act as a ballast gas and simplifying the separation process, leading to a more efficient and cost-effective production method.
Implementation Method 1
Separating ethane completely from an ethylene product stream may be done by use of an ethylene/ethane splitter which comprises a relatively large distillation column having a relatively large number of distillation stages. The boiling point difference between ethylene and ethane is relatively small: boiling point ethylene=−104° C.; boiling point ethane=−89° C.
Implementation Method 2
producing ethylene oxide by subjecting ethylene and ethane from the stream comprising ethylene and ethane, in which stream the amount of ethylene is greater than the amount of ethane, to oxidation conditions resulting in a stream comprising ethylene oxide, unconverted ethylene and ethane
Data Source
AI summary
The invention relates to a process for the production of ethylene oxide, comprising the steps of: producing ethylene resulting in a stream comprising ethylene and ethane; separating the stream comprising ethylene and ethane into a stream comprising ethylene and ethane in which stream the amount of ethylene is greater than the amount of ethane and a stream comprising ethane and ethylene in which stream the amount of ethane is greater than the amount of ethylene; producing ethylene oxide by subjecting ethylene and ethane from the stream comprising ethylene and ethane, in which stream the amount of ethylene is greater than the amount of ethane, to oxidation conditions resulting in a stream comprising ethylene oxide, unconverted ethylene and ethane; and recovering ethylene oxide from the stream comprising ethylene oxide, unconverted ethylene and ethane.