Integrated Feed Stripper Vent Recovery for Catalyst Poison Removal
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Solution Overview
Problem
Current methods for removing volatile catalyst poisons from liquid hydrocarbons in polyolefin polymerization systems are inefficient, leading to significant hydrocarbon losses and high energy costs, with existing systems requiring multiple independent stripping systems and resulting in high inert gas content in flare streams, which complicates efficient burning and recovery of hydrocarbons.
Innovation Solution
An integrated system and method that combines multiple liquid hydrocarbon streams into a single stripper column, utilizing a recycle gas system to remove volatile catalyst poisons and non-condensable gases, while recycling valuable monomers and comonomers, and adjusting stripper column pressure and gas flow rates to optimize volatile catalyst poison removal and hydrocarbon recovery.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If multiple independent stripping systems are used for each liquid hydrocarbon feed stream, then volatile catalyst poisons can be removed effectively, but investment cost and device complexity increase significantly
Solution Approach 1:
The patent combines multiple independent stripping systems into a single integrated stripping system that can handle multiple liquid hydrocarbon feed streams simultaneously. This merging approach reduces the number of separate columns, reboilers, and auxiliary equipment needed, thereby reducing investment cost and device complexity while maintaining effective volatile catalyst poison removal through unified operation
Solution Approach 2:
The integrated stripping system is designed to perform multiple functions: it can strip volatile catalyst poisons from different liquid hydrocarbon feed streams (such as comonomers and induced condensing agents) using a single column configuration. The system achieves multi-functionality by handling diverse feed streams with unified stripping parameters, reducing the need for dedicated stripping equipment for each stream
2Reliability
If traditional stripping systems are used, then volatile catalyst poisons are removed, but hydrocarbon losses in vent streams are high
Solution Approach 1:
The patent implements a hydrocarbon recovery system that captures valuable hydrocarbons from the stripper vent stream. Instead of directly venting the stripped gases to atmosphere or flare, the system condenses and recycles the hydrocarbon-containing vapors back to the process, thereby recovering lost hydrocarbons and reducing both material loss and environmental impact while maintaining effective poison removal
3Reliability
If reboiler-based distillation systems are used, then volatile catalyst poisons can be removed, but energy consumption is high
Solution Approach 1:
The patent modifies the operating parameters of the stripping system by operating at lower temperatures and pressures compared to traditional reboiler-based distillation. This parameter change allows for effective volatile catalyst poison removal through gas stripping rather than thermal distillation, significantly reducing energy consumption while maintaining stripping efficiency for the specific application
4Ease of manufacture
If packed bed stripping with inert gas is used, then investment cost is reduced, but hydrocarbon losses in vent stream increase
Solution Approach 1:
The patent incorporates a hydrocarbon recovery system that captures and condenses valuable hydrocarbons from the stripper vent stream. This recovery mechanism addresses the hydrocarbon loss issue by recycling the vented hydrocarbons back to the process, thereby maintaining the cost-effectiveness of the packed bed stripping approach while eliminating the disadvantage of high hydrocarbon losses
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 hydrocarbon venting to flares, conserves valuable monomers and comonomers, and optimizes the removal of volatile catalyst poisons, thereby enhancing the efficiency and cost-effectiveness of polyolefin polymerization processes by integrating hydrocarbon recovery and volatile catalyst removal operations.
Implementation Method 1
As the inert gas flows upward, volatile catalyst poisons transfer from the liquid into the inert gas
Implementation Method 2
hydrocarbons from a polymerization process vent stream
Data Source
AI summary
Systems and methods for removing a volatile catalyst poison from a liquid hydrocarbon are provided. In one embodiment, a process vent (106) can be introduced to a vent recovery system (108) to provide a recycle gas (110). A first portion of the recycle gas (112) and a liquid hydrocarbon (102) can be introduced to a stripper column (104) to provide a stripper vent gas (114) and a degassed liquid hydrocarbon (116) that can be introduced to a polymerization process.