Integrated FCC-OPDH Process Using CO2 as Mild Oxidant
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Solution Overview
Problem
The increasing demand for light olefins like propylene and ethylene is not met by conventional sources, leading to high prices, and existing alkane dehydrogenation processes face limitations due to high temperatures causing thermal cracking and catalyst deactivation, while also requiring hazardous oxygen as a promoter, which is costly and poses safety risks.
Innovation Solution
An integrated process combining Fluid Catalytic Cracking (FCC) with Oxidative Dehydrogenation (ODH) using carbon dioxide from FCC flue gas as a mild oxidant to convert alkanes to alkenes, enhancing yield and reducing CO2 emissions, by utilizing alkanes from the C3 and C4 hydrocarbon streams and CO2 from FCC regenerators.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If conventional dehydrogenation processes use high temperatures to achieve economically feasible conversions, then alkane conversion is improved, but thermal cracking occurs lowering selectivity and catalyst deactivation accelerates
Solution Approach 1:
The invention changes the chemical environment by introducing carbon dioxide as a mild oxidant, transforming the reaction conditions from purely thermal to oxidative. This parameter change allows dehydrogenation to proceed at lower temperatures while maintaining high conversion, resolving the contradiction between conversion and selectivity
Solution Approach 2:
Carbon dioxide acts as an intermediary substance that facilitates the dehydrogenation reaction by providing a controlled oxidizing environment. It enables the reaction to proceed through a different mechanism that avoids thermal cracking while maintaining high conversion rates and selectivity
2Productivity
If conventional dehydrogenation processes use high temperatures to achieve economically feasible conversions, then alkane conversion is improved, but catalyst deactivation accelerates
Solution Approach 1:
By changing the reaction conditions from high-temperature thermal dehydrogenation to lower-temperature oxidative dehydrogenation using carbon dioxide, the invention reduces the rate of catalyst deactivation while maintaining high conversion, thereby extending catalyst life
Solution Approach 2:
The invention converts carbon dioxide, a harmful greenhouse gas, into a beneficial mild oxidant that enables low-temperature dehydrogenation. This transforms an environmental problem into a solution that protects the catalyst from high-temperature deactivation
3Productivity
If oxygen is used as a promoter in dehydrogenation reaction to shift equilibrium and burn coke, then alkane conversion is improved, but safety risks increase due to explosive mixtures
Solution Approach 1:
The invention replaces hazardous oxygen with carbon dioxide, a non-flammable and inherently safer gas. This substitution eliminates the risk of explosive mixtures while maintaining the ability to shift dehydrogenation equilibrium and burn coke through controlled oxidation
Solution Approach 2:
The invention transforms carbon dioxide, traditionally viewed as a waste product or pollutant, into a valuable mild oxidant that improves conversion while eliminating safety hazards associated with oxygen use
4Manufacturing precision
If carbon dioxide is used as a mild oxidant in oxidative dehydrogenation, then propylene selectivity is improved, but CO2 emissions increase
Solution Approach 1:
The invention converts carbon dioxide emissions, a harmful environmental factor, into a useful reactant for oxidative dehydrogenation. By using CO2 as a mild oxidant, the process improves propylene selectivity while utilizing rather than emitting the greenhouse gas, effectively converting a waste stream into a valuable chemical input
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 increases the yield of propylene, ethylene, and butylenes while reducing CO2 emissions, improving catalyst life and reducing the need for hazardous oxygen, achieving higher alkane conversions with enhanced selectivity and energy efficiency.
Implementation Method 1
oxidative dehydrogenation of propane to propylene in the presence of carbon dioxide
Implementation Method 2
dehydrogenation of propane (or any alkane) is an endothermic reaction
Implementation Method 3
catalytic ODH, wherein the ODH process utilizes carbon dioxide from flue gas
Implementation Method 4
CO2 not only suppresses the unwanted total oxidation products due to its lower oxidizing ability
Implementation Method 5
carbon dioxide from flue gas of FCC regenerator
Data Source
AI summary
The present invention is related to an integrated process for enhancing the yields of propylene and other light olefins from Fluid catalytic cracking (FCC) process in combination with Oxidative propane dehydrogenation (OPDH) where in a hydrocarbon stream from Propylene recovery section consisting of propane predominantly, is converted to high value light olefins primarily C3 and C2 olefins by catalytic oxidative dehydrogenation using carbon dioxide from FCC flue gas exiting the regenerator. Several process configurations for the conversion of C3 and C4 alkanes to their respective alkenes separately or simultaneously by integrating with FCC are provided.