Methane Dilution in Alkane Oxidative Dehydrogenation
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Solution Overview
Problem
Current alkane oxidative dehydrogenation processes face challenges in achieving high conversion and productivity of C2-6 alkanes to their corresponding alkenes while maintaining safe and efficient operation.
Innovation Solution
An alkane oxidative dehydrogenation process involving a stream with a methane to C2-6 alkane volume ratio of 0.005:1 to 100:1, using a mixed metal oxide catalyst containing molybdenum, vanadium, and niobium, which allows for high conversion and productivity of C2-6 alkenes and optional carboxylic acids under oxydehydrogenation conditions.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If conventional alkane oxidative dehydrogenation processes are used, then the process can operate, but conversion and productivity of C2-6 alkane to C2-6 alkene are insufficient
Solution Approach 1:
Methane is introduced as an intermediary substance to mediate the oxidative dehydrogenation reaction. The methane acts as a heat sink and reaction moderator, enabling higher conversion rates while maintaining safe operating conditions by controlling the exothermicity of the process.
Solution Approach 2:
The process changes the compositional parameters of the feed stream by incorporating methane in specific volume ratios (0.005:1 to 100:1). This parameter modification allows the system to achieve higher alkane conversion while controlling reaction temperature and maintaining safety through altered thermal characteristics.
2Productivity
If high conversion of C2-6 alkane is achieved, then productivity increases, but heat management becomes more difficult due to exothermic reaction
Solution Approach 1:
The exothermic heat of the oxidative dehydrogenation reaction, which is normally a harmful byproduct requiring complex cooling systems, is converted into a beneficial feature by using methane as a heat sink. The methane absorbs the reaction heat, preventing runaway temperature increases while maintaining high conversion rates.
Solution Approach 2:
Methane serves as a thermal intermediary that absorbs excess heat from the exothermic dehydrogenation reaction. This intermediary substance enables the system to handle high conversion rates without requiring complex temperature control systems, as the methane naturally buffers the thermal energy.
3Reliability
If additional inert gases are added to control reaction conditions, then safety improves, but process complexity and cost increase
Solution Approach 1:
Methane performs multiple functions simultaneously: it acts as a safety diluent (replacing traditional inert gases), a heat sink for temperature control, and a process simplifier by eliminating the need for separate inert gas addition systems. This multi-functionality reduces both equipment complexity and operational costs.
Solution Approach 2:
The process uses methane, which is already present in the feed stream or readily available, to provide safety and temperature control functions that would otherwise require additional inert gases and associated equipment. The system essentially uses its own components to regulate itself, eliminating the need for external safety additives.
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 achieves high conversion and productivity of C2-6 alkanes to alkenes, simplifies the separation process, and reduces the need for additional inert gases, resulting in cost savings and safer operation by diluting the feed with methane, which dissipates exothermic heat effectively.
Implementation Method 1
Mixed metal oxide catalysts containing molybdenum (Mo), vanadium (V), niobium (Nb) and optionally tellurium (Te) as the metals, can be used as oxydehydrogenation catalysts
Implementation Method 2
diluting the feed with methane, which dissipates exothermic heat effectively
Implementation Method 3
oxidatively dehydrogenate alkanes, such as alkanes containing 2 to 6 carbon atoms (C2-6 alkanes), for example ethane or propane resulting in ethylene and propylene (C2-6 alkenes), respectively, in an oxidative dehydrogenation (oxydehydrogenation; ODH) process
Data Source
AI summary
The invention relates to a process of the oxidative dehydrogenation of a C2-6 alkane, comprising subjecting a stream comprising methane and the C2-6 alkane, in which stream the volume ratio of methane to the C2-6 alkane is of from 0.005:1 to 100:1, to oxydehydrogenation conditions resulting in a stream comprising methane, a C2-6 alkene and optionally a C2-6 carboxylic acid.