Ethylene Separation via Dual Deethanizer Segmentation
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Solution Overview
Problem
The existing ethylene separation processes face bottlenecks and high costs due to limitations in equipment, especially when an acetylene converter is located downstream of the deethanizer column, making it difficult to increase ethylene production without significant changes to existing infrastructure.
Innovation Solution
The process involves adding a second deethanizer column and acetylene converters to the conventional deethanizer column setup, where the C2 stream is split and refluxed to enhance ethylene separation, allowing high-purity ethylene streams to be fed into an ethylene separation column, thereby increasing ethylene production without requiring new equipment.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If a conventional single deethanizer column is used, then the equipment complexity is low, but the ethylene production is limited due to bottleneck constraints
Solution Approach 1:
The conventional single deethanizer column is segmented into two separate deethanizer columns (first deethanizer and second deethanizer) operating in parallel. Each column handles a portion of the C2 stream, allowing independent optimization and increased overall ethylene production capacity without requiring complete redesign of the existing facility
Solution Approach 2:
The process introduces a new dimensional aspect by adding a second deethanizer column that operates independently from the first, creating an additional processing dimension. This allows the system to handle larger volumes and achieve higher ethylene production without proportionally increasing the complexity of individual column operations
2Ease of operation
If the acetylene converter is located downstream of the deethanizer column, then the existing equipment configuration is maintained, but it is difficult to separate acetylene from ethylene product effectively
Solution Approach 1:
The C2 stream is divided into multiple streams after the first deethanizer, with specific portions directed to the second deethanizer for enhanced separation. This segmentation allows acetylene to be effectively removed from the ethylene product stream while maintaining the downstream acetylene converter configuration
Solution Approach 2:
The second deethanizer column acts as an intermediary processing unit between the first deethanizer and the downstream acetylene converter. It provides an additional separation stage that improves ethylene purity before the stream reaches the acetylene converter, effectively mediating the separation challenge
3Productivity
If existing equipment is changed to increase ethylene production, then the bottleneck is removed, but the cost increases significantly
Solution Approach 1:
By segmenting the C2 processing into two parallel deethanizer columns, the system increases ethylene production capacity using relatively simple additional equipment rather than costly modifications to existing units. The segmented approach allows incremental capacity expansion at lower cost
Solution Approach 2:
The second deethanizer column is designed to handle multiple functions: separating C2 from C3, removing acetylene from ethylene, and providing flexible feedstock for the downstream acetylene converter. This multi-functionality increases productivity while minimizing the need for specialized expensive equipment
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 enables a significant increase in ethylene production per unit volume with high ethylene purity, reducing energy consumption and equipment load, and can be applied to facilities with acetylene converters downstream of deethanizer columns, achieving ethylene purity of 99% or more economically.
Implementation Method 1
feeding the feed stream comprising the C2 stream and the C3 stream into a first deethanizer (DeC2) column to discharge a first C2 stream at the top and the C3 stream at the bottom of the first deethanizer column
Implementation Method 2
feeding a portion of the first C2 stream discharged at the top of the deethanizer column into a second deethanizer column to discharge a second C2 stream
Implementation Method 3
supplying the second C2 stream into a first acetylene converter to convert acetylene contained in the second C2 stream into ethylene
Data Source
AI summary
The present invention provides an ethylene separation process comprising an first and second deethanizer columns and an acetylene converter, thereby providing an ethylene stream having a purity of 99 wt % or more to the middle of an ethylene separation column. The present invention increases the production amount of ethylene and also reduces energy consumption by passing the feed through a preliminary ethylene separation process, without having to change existing facilities in which an acetylene converter is provided downstream of the deethanizer column.