Heat-Integrated Olefin Oligomerization for Low-Energy Distillation
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Solution Overview
Problem
Existing olefin oligomerization processes face high energy costs and CO2 emissions due to the use of heating steam in distillation columns, and increasing conversion rates leads to additional energy consumption and inefficiencies.
Innovation Solution
A process involving multiple reaction stages with heterogeneous catalysts, utilizing heat transfer media to recycle energy within the system, reducing the need for external heating steam and minimizing CO2 emissions.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If heating steam is used to heat distillation columns for separating oligomers from olefins, then separation efficiency is improved, but energy costs and CO2 emissions increase significantly
Solution Approach 1:
The invention converts the harmful waste heat from the exothermic oligomerization reaction into a beneficial resource by using it to heat the distillation columns. The reaction heat that would otherwise be discarded is now utilized to provide the necessary heating for separating oligomers from olefins, eliminating the need for external heating steam and its associated energy costs and CO2 emissions.
Solution Approach 2:
The invention merges the heating function with the reaction process itself. By integrating the heat transfer medium system that captures reaction heat and redirects it to distillation columns, the process combines the exothermic reaction's heat output with the endothermic distillation heat requirement, creating a self-sustaining thermal system that reduces external energy input.
2Manufacturing precision
If heating steam is used to heat distillation columns, then separation of oligomers is achieved, but CO2 emissions increase
Solution Approach 1:
The invention converts the harmful waste heat from the exothermic oligomerization reaction into a beneficial resource by using it to heat the distillation columns. The reaction heat that would otherwise be discarded is now utilized to provide the necessary heating for separating oligomers from olefins, eliminating the need for external heating steam and its associated energy costs and CO2 emissions.
3Productivity
If conversion rate is increased to ensure sustainable utilization of feed stream, then productivity is improved, but additional energy consumption in form of heating steam increases
Solution Approach 1:
The invention establishes a continuous heat recycling loop where reaction heat is continuously captured, transferred through the heat transfer medium, and applied to distillation columns. This continuous thermal integration ensures that as conversion rates increase and more oligomerization reaction occurs, the corresponding increase in reaction heat automatically provides the necessary heating for enhanced separation, maintaining energy efficiency at higher productivity levels.
Solution Approach 2:
The invention converts the harmful waste heat from the exothermic oligomerization reaction into a beneficial resource by using it to heat the distillation columns. The reaction heat that would otherwise be discarded is now utilized to provide the necessary heating for separating oligomers from olefins, eliminating the need for external heating steam and its associated energy costs and CO2 emissions.
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 process achieves significant energy savings and lower CO2 emissions while maintaining high conversion rates, enhancing operational efficiency and cost-effectiveness.
Implementation Method 1
the energy generated during the condensation of the dimer stream D1 and the thermal energy generated in the at least one reactor of the first reaction stage R1 are at least partly transferred to a liquid or gaseous heat transfer medium W1
Implementation Method 2
which is first compressed and/or heated and via which a vapor stream is then generated with the aid of single-stage or multi-stage compression
Implementation Method 3
the dimer stream D1 is obtained at the top of the DKA1, is condensed and is then partly returned to the DKA1 as reflux
Implementation Method 4
a feed mixture which contains at least the C2 to C8 olefins as reactant olefins, in which at least one reactor of the first reaction stage R1 is subjected to oligomerization using a heterogeneous catalyst
Data Source
Figure 1~2
Figure 3~4
Figure 5~6
AI summary
The present invention relates to a process for the oligomerization of C2 to C8 olefins in at least two reaction stages, each comprising at least one reactor and at least one distillation column, and a subsequent separation stage comprising at least one distillation column, wherein reaction heat and/or the condensation energy is utilized by means of a heat transfer medium.