Methods and systems for separating olefins
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Solution Overview
Problem
Current methods for separating ethane and ethylene from hydrocarbon mixtures require low temperature and high pressure processes, leading to significant capital and operating costs due to the need for dual refrigerant systems and specialized equipment, which is inefficient and costly.
Innovation Solution
A system and method that involves separating C3 and heavier hydrocarbons from a hydrocarbon mixture containing C1 to C20 hydrocarbons, hydrogenating acetylene to ethane and ethylene, and then separating ethane and ethylene at pressures between 360 kPa and 4,000 kPa to produce products with purities greater than 95 mol %, reducing the need for low temperature refrigeration.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If low temperature vapor-liquid flash and fractional distillation processes are used to separate ethane and ethylene, then separation purity greater than 95 mol % is achieved, but capital costs and operating costs increase significantly due to dual refrigerant systems and specialized equipment
Solution Approach 1:
The patent changes the operating parameters from low temperature to high temperature by introducing water vapor into the distillation column. This allows the separation process to operate at temperatures above the boiling point of water, eliminating the need for complex low-temperature refrigeration systems while maintaining separation purity greater than 95 mol % for ethane and ethylene products
Solution Approach 2:
Water vapor is introduced as an intermediary substance into the distillation column to modify the vapor-liquid equilibrium. The water vapor acts as a carrier gas that enables high-temperature operation and improves the relative volatility between ethane and ethylene, allowing separation without complex refrigeration while achieving the required purity levels
2Manufacturing precision
If low temperature fractional distillation is used to separate ethane and ethylene, then high purity products are obtained, but energy consumption increases due to dual refrigeration systems
Solution Approach 1:
The patent changes the temperature parameter from low temperature to high temperature operation by introducing water vapor. This eliminates the need for energy-intensive refrigeration systems while maintaining separation purity greater than 95 mol %. The high-temperature process uses the natural volatility differences of hydrocarbons at elevated temperatures, significantly reducing energy consumption
Solution Approach 2:
The patent converts the typically harmful effect of water contamination in hydrocarbon streams into a beneficial effect. By introducing controlled amounts of water vapor, the process achieves high-temperature operation that eliminates refrigeration needs and improves separation efficiency, turning a potential contaminant into a process enabler that reduces energy consumption
3Productivity
If high pressure separation processes are used, then separation efficiency improves, but equipment construction costs increase due to special metallurgy requirements
Solution Approach 1:
The patent changes the pressure-temperature operating conditions by introducing water vapor, allowing the process to operate at high temperatures without requiring high pressures. This eliminates the need for expensive high-pressure equipment with special metallurgy while maintaining high separation efficiency through the improved volatility relationships at elevated temperatures
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 allows for the efficient separation of ethane and ethylene with reduced energy consumption and operational costs by eliminating the need for dual refrigerant systems and enabling separation at higher pressures, thereby improving the overall process efficiency.
Implementation Method 1
hydrogenating at least a portion of the first hydrocarbon mixture to convert at least a portion of the acetylene to ethane and ethylene
Implementation Method 2
separating at least a portion of the ethylene from the second hydrocarbon mixture to provide a first product comprising at least 95 mol % ethylene and a second product comprising at least 95 mol % ethane at a pressure of about 360 kPa to about 4,000 kPa
Data Source
AI summary
Systems and methods for separating one or more olefins are provided. In one or more embodiments, the method for separating one or more olefins can include separating at least a portion of one or more C3 and heavier hydrocarbons from a hydrocarbon containing C1 to C20 hydrocarbons to provide a first mixture that can include methane, ethane, ethylene, and/or acetylene. At least a portion of the first mixture can be hydrogenated to convert at least a portion of the acetylene to ethane and ethylene. At least a portion of the methane can be separated from the hydrogenated mixture to provide a second mixture that can include ethane and ethylene. At least a portion of the ethylene can be separated from the second mixture to provide a first product that can include at least 95 mol % ethylene and a second product that can include at least 95 mol % ethane.