Integrated OCM Dimerization Metathesis Propylene Production
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Solution Overview
Problem
There is a need for efficient and commercially viable systems and methods for converting alkanes into olefins, particularly for integration with crude to chemicals (C2C) processes such as high-severity fluidized catalytic cracking (HS-FCC) and processes employing dimerization and metathesis operations.
Innovation Solution
The integration of an oxidative-coupling of methane (OCM) process with dimerization and metathesis operations, where methane and an oxidizing agent are injected into an OCM reactor to produce ethylene, which is then converted into butene in a dimerization reactor, and subsequently into propylene in a metathesis reactor, with optional recycling and purification steps to enhance efficiency.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If oxidative coupling of methane (OCM) process is integrated with dimerization and metathesis operations, then propylene production efficiency is improved, but process complexity increases
Solution Approach 1:
The patent combines three separate chemical processes (OCM, dimerization, and metathesis) into an integrated flow where the product of one process becomes the feedstock for the next. The OCM reactor produces ethylene which is directly fed to the dimerization reactor to produce butene, which then enters the metathesis reactor to produce propylene. This merging of processes improves overall productivity by creating a continuous conversion pathway from methane to propylene, while the complexity is managed through systematic process design and catalyst selection.
2Ease of manufacture
If multiple reaction steps (OCM, dimerization, metathesis) are implemented in sequence, then olefin conversion efficiency is improved, but manufacturing complexity increases
Solution Approach 1:
The patent divides the overall conversion process into three distinct reaction stages, each with its own optimized reactor and catalyst system. The OCM stage uses specific catalysts for methane coupling, the dimerization stage uses catalysts optimized for ethylene to butene conversion, and the metathesis stage uses catalysts for butene to propylene conversion. This segmentation allows each step to be independently optimized for its specific chemical transformation, improving overall conversion efficiency while managing manufacturing complexity through modular process design.
3Productivity
If high severity fluidized catalytic cracking (HS-FCC) is used for crude to chemicals conversion, then olefin yield is improved, but process integration difficulty increases
Solution Approach 1:
The patent creates a multi-functional process system where the OCM-dimerization-metathesis sequence can serve multiple purposes: converting methane to propylene, utilizing off-gas streams from other refinery operations, and integrating with existing HS-FCC units. The process can handle various feedstock compositions and produce multiple olefin products, making it a universal solution that can be integrated into different crude-to-chemicals configurations without requiring complete process redesign.
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 enables the efficient production of propylene by effectively converting methane into propylene through a series of integrated chemical reactions, improving the yield and efficiency of olefin production in C2C processes.
Implementation Method 1
injecting a first stream containing methane and a second stream containing an oxidizing agent into an oxidative coupling of methane (OCM) reactor to produce a stream containing ethylene
Implementation Method 2
injecting the ethylene into a dimerization reactor to produce butenes including 1-butene, 2-butene, and isobutene
Implementation Method 3
injecting the butenes into a metathesis reactor to produce an effluent comprising propylene and unconverted butene
Data Source
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AI summary
The present disclosure provides methods and systems for producing an olefin, such as ethylene and propylene. A method for producing an olefin can comprise injecting an oxidizing agent and methane into an oxidative coupling of methane (OCM) reactor to generate ethylene. The methane and/or additional feedstocks for the OCM reactor can be derived from a thermal cracking or fluidized catalytic cracking (FCC) process. The ethylene generated in the OCM reactor can be converted to propylene through a dimerization unit and metathesis unit.