Hydrocarbon Stream Purification With Integrated Sorption Hydrogenation
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Solution Overview
Problem
Existing purification processes for hydrocarbon streams, particularly propellant gases like propane and isobutane, are complex, costly, and inefficient in removing unwanted substances and olefins, requiring frequent adsorber changes and additional hydrogenation steps, leading to high costs and multistage processes.
Innovation Solution
A process involving a single distillation column to separate low and high boilers, followed by sorption in the presence of hydrogen for hydrogenation of olefins, using a sorbent with a specific composition for further purification, achieving a hydrocarbon stream with over 98% Cx alkanes.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If sorption methods are used to remove unwanted substances, then purification is achieved, but adsorbers require frequent cleaning and replacement, increasing costs and complexity
Solution Approach 1:
The patent combines sorption and hydrogenation functions into a single integrated unit. The sorbent material performs both adsorption of unwanted substances and catalytic hydrogenation of olefins simultaneously, eliminating the need for separate adsorber and hydrogenation reactor systems. This reduces device complexity while maintaining high purification quality.
Solution Approach 2:
The sorbent material is designed to perform multiple functions: adsorbing odour-forming substances, absorbing residual low and high boilers, and catalyzing hydrogenation of olefins in the presence of hydrogen. This multi-functionality eliminates the need for multiple separate processing units and their associated regeneration systems.
2Manufacturing precision
If multiple separate separation steps are used for low boilers and high boilers, then chain length distribution is controlled, but process complexity and costs increase
Solution Approach 1:
The patent uses a single distillation column to separate both low boilers (Cx-1 hydrocarbons) and high boilers (Cx+1 hydrocarbons) from the medium boiler stream (Cx alkanes). The column is designed with appropriate feed and product withdrawal points to achieve simultaneous separation of lighter and heavier components, eliminating the need for multiple separate distillation columns.
3Manufacturing precision
If additional hydrogenation step is added for olefin removal, then reactive components are eliminated, but process complexity and costs increase
Solution Approach 1:
The hydrogenation function is integrated into the sorption unit by incorporating a hydrogenation catalyst within the sorbent material or as a coating. Hydrogen is fed into the sorption unit where it reacts with olefins on the catalyst surface, converting them to alkanes. This eliminates the need for a separate hydrogenation reactor and simplifies the overall process.
4Manufacturing precision
If frequent adsorber changes are implemented, then purification quality is maintained, but operational costs and downtime increase
Solution Approach 1:
The multifunctional sorbent catalyst performs adsorption and hydrogenation simultaneously, creating a more robust purification system that doesn't require frequent changes. The hydrogenation function permanently converts adsorbable olefins to non-adsorbable alkanes, reducing the burden on the sorbent and extending its operational life while maintaining consistent purification quality.
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 simplifies plant component integration, reduces costs, and achieves high purity (>98% Cx alkanes) with minimal sorbent regeneration needs, effectively removing odorous and reactive compounds.
Implementation Method 1
separating off at least a portion of the low boilers and separating off at least a portion of the high boilers in a single distillation column
Implementation Method 2
removing at least a portion of the remaining low boilers and/or at least a portion of the remaining high boilers from the medium boiler intermediate obtained from step a) by means of sorption in a sorption unit
Implementation Method 3
the sorption in step b) is conducted in the presence of hydrogen, and in that a hydrogenation of at least a portion of the olefins present additionally takes place in the sorption unit
Data Source
AI summary
A process can be used for purifying a hydrocarbon stream containing at least Cx alkanes, Cx olefins, low boilers such as Cx−1 hydrocarbons, and high boilers such as Cx+1 hydrocarbons, with x=3 or 4. The process involves separating off low boilers and separating off high boilers, wherein the separating-off of high boilers is performed in the presence of hydrogen and hence a hydrogenation of the olefins present takes place.