Olefin Conversion via Isomerization and Metathesis
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Solution Overview
Problem
Current processes for producing high purity alpha-olefins, such as 1-butene, 1-hexene, and 1-octene, are energy intensive due to the need for distillation to separate these olefins from their positional isomers, which have close boiling points, making them economically unattractive.
Innovation Solution
A process involving isomerization and metathesis reactions that convert propylene with a hydrocarbon mixture to form beta-olefins, which are then converted back to alpha-olefins using ethylene, allowing for easier separation and reducing the need for intensive fractionation systems like superfractionators.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If distillation is used to separate alpha-olefins from positional isomers, then high purity alpha-olefins are obtained, but energy consumption increases significantly
Solution Approach 1:
The invention changes the chemical structure parameter of the olefin from alpha-position to beta-position through isomerization, which fundamentally alters the boiling point characteristics and enables easier separation. This parameter change transforms the separation problem from one requiring energy-intensive superfractionation to one amenable to conventional distillation
Solution Approach 2:
The invention introduces beta-olefin as an intermediate substance in the production process. By converting alpha-olefin to beta-olefin and then back to alpha-olefin through controlled reactions, the process uses this intermediate to achieve both high purity and reduced energy consumption, as the beta-olefin intermediate has different separation characteristics
2Manufacturing precision
If superfractionators are used to separate 1-hexene from 2-hexene and 3-hexene, then high purity 1-hexene is produced, but the process becomes economically unattractive due to high operating costs
Solution Approach 1:
The invention applies parameter change by isomerizing 1-hexene to 2-hexene, which has different physical properties including boiling point. This parameter transformation allows separation through conventional distillation rather than requiring expensive superfractionators, thereby improving economic viability while maintaining product purity
Solution Approach 2:
The invention uses inversion by first converting the desired product (1-hexene) to its isomer (2-hexene), separating the isomer, and then converting it back. This reverse approach avoids the need for direct separation of close-boiling isomers and reduces equipment costs and operating expenses
3Manufacturing precision
If multiple superfractionators are deployed for 1-hexene production, then separation completeness is achieved, but device complexity and capital investment increase
Solution Approach 1:
The invention changes the chemical parameter of the hexene isomer from the 1-position to the 2-position, which creates sufficient boiling point difference to enable complete separation using a single conventional distillation tower instead of multiple superfractionators, thereby reducing device complexity
Solution Approach 2:
The invention employs 2-hexene as an intermediate that facilitates separation. By converting 1-hexene to 2-hexene, performing the separation, and then converting back, the process uses this intermediate to achieve complete separation with simpler equipment, reducing the number of towers from multiple to one
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 significantly reduces energy consumption by simplifying the separation of alpha-olefins from their positional isomers, making the production of high purity alpha-olefins more economically viable without the need for energy-intensive distillation.
Implementation Method 1
contacting propylene and a hydrocarbon mixture comprising a mixture of olefins having a carbon number n with a first metathesis catalyst to form a metathesis product comprising a beta-olefin having a carbon number n+1, an alpha-olefin having a carbon number n−1
Implementation Method 2
contacting a hydrocarbon mixture comprising linear butenes with an isomerization catalyst to form an isomerization product comprising 2-butenes and 1-butenes
Implementation Method 3
fractionating the metathesis product to recover a fraction comprising the beta-olefin having a carbon number n+1
Data Source
AI summary
Processes for the production of high purity alpha olefins from a mixture of olefins are disclosed. The processes may include: contacting propylene and a hydrocarbon mixture comprising a mixture of olefins having a carbon number n with a first metathesis catalyst to form a metathesis product comprising a beta-olefin having a carbon number n+1, an alpha-olefin having a carbon number n−1, as well as any unreacted propylene and olefins having a carbon number n. The metathesis product may be fractionated to recover a fraction comprising the beta-olefin having a carbon number n+1. Ethylene and the fraction comprising the beta-olefin having a carbon number n+1 may then be contacted with a second metathesis catalyst to form a second metathesis product comprising an alpha-olefin having a carbon number n and propylene, which may be fractionated to form a propylene fraction and a fraction comprising the alpha olefin having a carbon number n.