Gaseous Feed OTO Reactor for Pressure Loss Reduction
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Solution Overview
Problem
Current oxygenate-to-olefin (OTO) synthesis processes for producing short-chain olefins like ethylene and propylene are complex, energy-intensive, and prone to catalyst deactivation due to high pressure drops and complex vapor/liquid distribution systems, which limits operational flexibility and increases costs.
Innovation Solution
A simplified process where all reactant mixture partial streams, steam streams, and recycle streams are introduced into the OTO synthesis reactor in gaseous form, eliminating the need for two-phase nozzles and reducing pressure losses, with a gaseous etherification reactor product mixture containing dimethyl ether, steam, and methanol vapor being directly fed to the reactor without additional separation, allowing for better temperature control and increased selectivity of target olefins.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If a complex vapor/liquid distribution system with two-phase nozzles is used to feed reactant mixture to the OTO reactor, then the reactant mixture can be supplied in both liquid and gaseous form, but the pressure drop increases and the system complexity increases
Solution Approach 1:
The invention changes the physical state parameter of the reactant mixture from liquid/two-phase to gaseous form before feeding into the OTO reactor. This parameter change eliminates the need for complex two-phase nozzles and vaporization systems, thereby reducing system complexity while maintaining feeding flexibility through gas-phase injection.
Solution Approach 2:
The invention extracts and removes the complex vaporization and two-phase distribution subsystem from the overall feeding system. By directly feeding pre-vaporized or gaseous reactant mixture into the OTO reactor, the patent eliminates the need for two-phase nozzles and associated control systems, simplifying the overall device architecture.
2Ease of operation
If a complex vapor/liquid distribution system is used to supply reactant mixture to the OTO reactor, then the reactant mixture can be distributed effectively, but the pressure losses increase
Solution Approach 1:
By changing the feed state to gaseous form, the invention reduces compression and pressure drop losses compared to liquid feeding systems. Gas-phase reactants require less energy for pressurization and distribution, and the simpler gas distribution network experiences lower pressure losses than complex two-phase flow systems.
3Manufacturing precision
If additional separation steps are performed on the etherification reactor product mixture, then the reactant mixture purity can be improved, but the energy consumption increases
Solution Approach 1:
The etherification reactor is designed to self-produce a gaseous product mixture that is directly suitable for OTO reactor feeding without requiring additional separation or purification steps. The reaction conditions and product composition naturally align with the requirements of the OTO process, eliminating the need for energy-intensive separation units.
4Quantity of substance
If the reactant mixture is fed in liquid form to the OTO reactor, then the reactant concentration can be maintained, but the temperature control becomes difficult due to vaporization requirements
Solution Approach 1:
The invention changes the feed state from liquid to gaseous form, which eliminates the need for endothermic vaporization within the reactor system. This parameter change allows for better temperature control since the exothermic OTO reaction is not competing with the endothermic vaporization process, enabling more stable thermal management and uniform temperature distribution in the catalyst zones.
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 energy consumption, simplifies the distribution system, lowers operational pressures, and enhances the selectivity and yield of ethylene and propylene by maintaining uniform reactant partial pressures across catalyst zones, thereby improving the overall efficiency and longevity of the catalyst.
Implementation Method 1
catalytic dehydration of methanol in the gas phase
Implementation Method 2
heterogeneously catalyzed processes
Implementation Method 3
the vaporization enthalpy required to vaporize the fine liquid droplets is withdrawn from the reaction sections and in particular the catalyst zones and thus ensures their cooling
Data Source
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AI summary
The invention relates to a process and a plant for the production of an olefin-containing hydrocarbon product by reacting an oxygenate-containing reactant mixture, which is divided into several reactant mixture partial streams, in a multi-stage oxygenate-to-olefin (OTO) synthesis reactor with several reaction sections comprising catalyst zones connected in series, wherein an injection device for a reactant mixture partial stream is arranged upstream of each catalyst zone. A reactant mixture partial stream is introduced into each of these reaction sections and there reacted under oxygenate conversion conditions to form olefins and further hydrocarbons, wherein all reaction sections except the first are additionally supplied with the product stream of the reaction section arranged upstream.Additionally, at least one steam stream and at least one hydrocarbon-containing recirculation stream are introduced into at least one reaction section. The OTO synthesis reactor product is fractionated in a multi-stage workup device, yielding several hydrocarbon product fractions, at least one of which is returned to the OTO synthesis reactor as a recirculation stream. According to the invention, all reactant mixture partial streams, steam streams, and recirculation streams are introduced into the OTO synthesis reactor in gaseous or vaporous form.