Integrated Olefin Process with CO2 Sequestration
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Solution Overview
Problem
There is a need for chemical processes that produce olefins and olefin derivatives with reduced carbon dioxide emissions, as existing processes contribute significantly to greenhouse gas emissions.
Innovation Solution
A process that converts alkanes to olefin monomers like ethylene, propylene, and butene using renewable electric power in an oxidative-coupling of methane (OCM) plant, with carbon dioxide sequestration from boiler stack gases, and employs solar heating and oxygen-enhanced combustion to minimize emissions.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If conventional chemical processes are used to produce olefins, then olefin production is achieved, but carbon dioxide emissions are significant
Solution Approach 1:
The patent captures carbon dioxide emissions from the olefin production process and converts this harmful byproduct into a beneficial resource by injecting it into an adjacent power plant's combustion process, where it displaces atmospheric oxygen and reduces the need for nitrogen-based dilution gases, thereby transforming the harmful emission into a process improvement for both facilities
Solution Approach 2:
The patent merges two previously separate processes - olefin production and power generation - into an integrated system where the olefin plant's carbon dioxide emissions are directly utilized by the power plant, creating a synergistic relationship that reduces overall greenhouse gas emissions while maintaining both olefin production and power generation capabilities
2Use of energy by stationary object
If fired equipment is used in the process, then heating and power generation are achieved, but nitrogen-based gas volumes increase and safety risks increase
Solution Approach 1:
The patent converts the harmful effect of high nitrogen volumes (which dilute the combustion atmosphere and reduce efficiency) into a benefit by using captured carbon dioxide to displace atmospheric air, thereby reducing nitrogen content in the combustion zone and improving combustion efficiency while maintaining safety
Solution Approach 2:
The patent changes the compositional parameters of the combustion atmosphere by injecting carbon dioxide, altering the oxygen-nitrogen-carbon dioxide ratio to reduce nitrogen-based gas volumes from the typical 70-80% to significantly lower levels, thereby improving process efficiency and safety
3Object-generated harmful factors
If carbon dioxide is captured and sequestered, then emissions are reduced, but process complexity increases
Solution Approach 1:
The patent merges the carbon dioxide capture function with the power plant's existing combustion process, eliminating the need for separate sequestration infrastructure such as compression, storage, or transport systems, thereby reducing overall process complexity while achieving emission reduction goals
Solution Approach 2:
The power plant serves its own need for combustion atmosphere control by utilizing the carbon dioxide produced by the adjacent olefin plant, creating a self-sufficient system where each facility provides a service to the other without requiring external intervention or complex additional equipment
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 results in substantially zero carbon emissions, reducing the environmental impact and improving safety by minimizing fired equipment and nitrogen-based gas volumes, while producing high-quality olefin derivatives like poly alpha olefins, propylene glycol, and acrylic acid.
Implementation Method 1
converting alkanes to the olefin monomers ethylene, propylene, and butene or combinations thereof using renewable electric power in an oxidative-coupling of methane (OCM) plant
Implementation Method 2
scrubbing at least one boiler stack gasses with a solvent to sequester carbon dioxide from the boiler stack gas
Implementation Method 3
employs solar heating and oxygen-enhanced combustion to minimize emissions
Implementation Method 4
employs solar heating and oxygen-enhanced combustion to minimize emissions
Data Source
AI summary
A substantially zero carbon emission process for making amorphous poly alpha olefins including, converting alkanes to olefin monomers ethylene, propylene, and 1-butene or combinations thereof using renewable electric power in an oxidative-coupling of methane plant including the steps of passing alkanes through an ethylene plant while adding oxygen, passing the first polymerization grade ethylene through a 2-butene plant, passing a first of the two 2-butene streams and one of the polymerization grade ethylene through a propylene plant, and passing a second of the two 2-butene streams through a 1-butene plant. The next step in the process for making amorphous poly alpha olefins includes polymerizing at least one of the polymerization grade alkenes which includes applying a temperature of 130 degrees Fahrenheit to 175 degrees Fahrenheit to at least one of the polymerization grade alkenes and scrubbing at least one boiler stack gases.