Flexible Butadiene Extraction Process Pressure Modes
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Solution Overview
Problem
Butadiene extraction processes from mixed hydrocarbon streams face challenges in flexibility and efficiency due to the need for significant changes in equipment and solvent heat recovery schemes when switching between high and low pressure operations, leading to increased capital investment costs and reduced process efficiency.
Innovation Solution
A butadiene extraction system and process that can operate at both high and low pressures with minimal additional capital investment, utilizing a feed vaporization system, extractive distillation, rectifier, afterwasher, degasser, and cooling column, which allows for flexible operation by retaining existing equipment and requiring only minor changes, such as an additional heat exchanger and adjustments to controls, to accommodate different pressure modes.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If the process operates in high pressure mode without compressor, then capital investment cost is reduced, but the solvent heat recovery scheme requires significant changes
Solution Approach 1:
The process is designed to dynamically switch between high pressure and low pressure operating modes. The system can adapt its configuration based on operational requirements, allowing the solvent heat recovery scheme to be reconfigured rather than permanently redesigned, thus reducing capital investment while maintaining flexibility.
Solution Approach 2:
The invention changes the operating pressure parameter to switch between operational modes. By operating at high pressure without a compressor, the system avoids capital investment costs associated with compressors and their associated heat recovery systems, while still achieving effective butadiene extraction through parameter adjustment.
2Productivity
If the process operates in low pressure mode with compressor, then separation efficiency is improved, but capital investment cost increases due to additional equipment
Solution Approach 1:
The system is designed with multi-functionality to perform both high pressure and low pressure operations using the same core equipment. The extractor and associated equipment serve multiple operational modes, eliminating the need for separate high-pressure and low-pressure systems, thus improving separation efficiency without proportionally increasing capital investment.
Solution Approach 2:
The process allows dynamic switching between operational modes based on separation efficiency requirements. When high separation efficiency is needed, the system can operate in low pressure mode with the compressor; when capital cost is the priority, it switches to high pressure mode without the compressor, providing flexibility in optimizing the efficiency-cost tradeoff.
3Ease of manufacture
If equipment is redesigned for high pressure operation, then compressorless operation is achieved, but process flexibility is reduced
Solution Approach 1:
The system is designed to be dynamic and adaptable, allowing switching between high pressure compressorless mode and low pressure mode with compressor. This dynamic capability ensures that the process maintains flexibility despite being optimized for high pressure operation, as it can transition between modes based on operational requirements.
Solution Approach 2:
The process configuration is segmented into modular components that can be independently configured for different pressure modes. The extractor, heat exchangers, and separation systems are designed as separable units that can be reconfigured or operated independently in different pressure regimes, maintaining process flexibility while achieving compressorless high pressure operation.
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
The system provides added process flexibility with minimal capital expenses, maintaining efficiency by retaining existing equipment and avoiding re-optimization of the solvent heat recovery system, allowing operation with or without a compressor, thus reducing operational costs and maintaining process efficiency across different pressure conditions.
Implementation Method 1
a feed vaporization system for at least partially vaporizing a hydrocarbon feed
Implementation Method 2
an extractive distillation system for contacting the vaporized hydrocarbon fraction with a solvent to selectively dissolve a portion of the hydrocarbon fraction
Implementation Method 3
a rectifier and afterwasher for at least partially degassing the enriched solvent and recovering a first vapor fraction
Data Source
Figure 1
AI summary
A butadiene extraction processes designed for flexible operations, with or without a compressor, is disclosed. The ability to run at both high and low pressures provides added process flexibility.