Integrated C4 Processing for High-Purity 1-Butene and Isobutane
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Solution Overview
Problem
Existing processes for producing high-purity 1-butene and isobutane require separate production lines, leading to high capital and operating costs and energy consumption.
Innovation Solution
A process that integrates the treatment of two C4 hydrocarbon streams in a single production plant, involving steps such as isobutane separation, alcohol reaction, product separation, and hydrogenation to produce high-purity 1-butene and isobutane streams.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If two separate production lines are operated to process two C4 hydrocarbon streams, then high-purity 1-butene and isobutane streams can be obtained, but capital costs and operating costs increase significantly
Solution Approach 1:
The patent combines the processing of two separate C4 hydrocarbon streams into a single production line. Stream A is processed through isobutane separation to form an isobutane-depleted stream, which is then mixed with stream B to create a combined stream C. This merged stream undergoes integrated processing including alcohol reaction, product separation, and hydrogenation, ultimately yielding both high-purity 1-butene and isobutane streams from one facility rather than requiring two separate production lines.
2Manufacturing precision
If two separate production lines are operated to process two C4 hydrocarbon streams, then high-purity 1-butene and isobutane streams can be obtained, but energy consumption increases
Solution Approach 1:
The patent merges the processing of two C4 streams into one integrated production line, reducing the total energy consumption associated with operating two separate facilities. The combined stream C is processed through shared units including the alcohol reaction unit, product separation system, and hydrogenation unit, eliminating redundant energy expenditures.
Solution Approach 2:
The single production line is designed to perform multiple functions: it processes both stream A and stream B, conducts isobutane separation, performs alcohol reaction to convert isobutene, executes product separation, and carries out hydrogenation. This multi-functional approach allows one facility to achieve what previously required two separate specialized lines, reducing overall energy consumption.
3Device complexity
If a single production plant is used to process two C4 hydrocarbon streams, then capital costs and energy costs are reduced, but maintaining high purity of product streams becomes more difficult
Solution Approach 1:
The patent applies segmentation by dividing the combined stream C into different processing paths. The alcohol reaction unit selectively converts isobutene to ATBE or dimers, separating this component from the mixture. The product separation unit then divides the residual stream into specific fractions, and the hydrogenation unit selectively hydrogenates 1,3-butadiene. These segmented processing steps ensure that each component is treated appropriately to maintain high product purity.
Solution Approach 2:
The patent utilizes parameter changes to achieve selective transformations and separations. The alcohol reaction changes the chemical state of isobutene by converting it to ATBE or dimers. The hydrogenation unit changes the saturation level of 1,3-butadiene by adding hydrogen. These parameter changes enable selective modification of specific components in the mixed stream, allowing high-purity product streams to be obtained from the combined feed.
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
Reduces capital and energy costs while maintaining the purity of the 1-butene and isobutane streams by integrating the processing of two C4 hydrocarbon streams in a single plant.
Implementation Method 1
at least a portion of the isobutene present in stream C is converted to ATBE (alkyl tert-butyl ether), preferably MTBE (methyl tert-butyl ether) or ETBE (ethyl tert-butyl ether), particularly preferably MTBE (methyl tert-butyl ether) and/or to isobutene dimers
Implementation Method 2
supplying the residual stream to a first separation unit, wherein in the first separation unit a low-boiler stream, containing at least 1,3-butadiene, 1-butene, 2-butene and isobutane, and a water-containing stream, containing at least alcohol, preferably methanol or ethanol
Implementation Method 3
supplying the low-boiler stream to a hydrogenation, in order to hydrogenate at least a portion of the 1,3-butadiene present
Implementation Method 4
supplying the hydrogenated low-boiler stream to a second separation unit, wherein in the second separation unit a stream D, containing at least isobutane and 1-butene, and a stream E, containing at least n-butane and 2-butene
Implementation Method 5
supplying stream D to a third separation unit, wherein in the third separation unit a crude isobutane stream and a stream of high-purity 1-butene are obtained
Implementation Method 6
supplying the crude isobutane stream to a fourth separation unit, wherein in the fourth separation unit an offgas stream and a stream of high-purity isobutane are obtained
Data Source
AI summary
A process produces high-purity 1-butene and high-purity isobutene from two C4 hydrocarbon streams, in which the two C4 hydrocarbon streams are in part processed together. An apparatus carries out the process.