Oligomer Separation Flow Using Settling Tank Polymer Removal
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Solution Overview
Problem
The production of α-olefins like 1-hexene and 1-octene is hindered by polymer fouling in reactors, leading to increased energy costs and reduced operation time due to the need for high-boiling point separation and solvent recovery processes, which are inefficient with high polymer content streams.
Innovation Solution
A method involving a settling tank to separate polymers from the reaction product before high-boiling point and solvent separation columns, allowing direct supply of a solvent-rich upper layer to the solvent separation column, thereby reducing energy consumption and stream flow rates in these columns.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a high-boiling point separation column and solvent separation column are provided to remove polymer and recover solvent, then polymer removal and solvent recovery are achieved, but energy costs and separation time are increased due to high polymer content in the input stream
Solution Approach 1:
A settling tank is introduced before the separation columns to preliminarily remove polymer from the reaction product. This preliminary action reduces the polymer content in the stream entering the high-boiling point separation column and solvent separation column, thereby reducing the energy required for these separation operations while maintaining effective polymer removal and solvent recovery
Solution Approach 2:
The separation process is segmented into multiple stages: first, polymer settling in a settling tank; second, high-boiling point material removal in a separation column; third, solvent separation in another column. This segmentation allows each unit operation to handle a specific task with optimized energy input, avoiding the need for one large energy-intensive separation step
2Reliability
If polymer accumulates in the reactor due to fouling phenomenon, then polymer removal is achieved, but reactor operation time is decreased and washing costs are increased
Solution Approach 1:
The polymer is extracted from the reaction system by introducing a settling tank where polymer settles out of the reaction product stream. The clarified liquid is then recycled back to the reactor, preventing polymer accumulation and fouling while maintaining continuous operation and high productivity
Solution Approach 2:
The polymer removal process is made continuous through the settling tank configuration, where polymer is continuously settled and removed from the recycled stream. This continuous action prevents reactor fouling without requiring periodic shutdowns for washing, thereby maintaining continuous productive operation
3Reliability
If polymer content in the stream supplied to separation columns is higher, then polymer removal is more thorough, but separation time and energy costs are increased
Solution Approach 1:
The settling tank performs preliminary polymer removal before the stream enters the separation columns. This preliminary action reduces the polymer load on the separation columns, allowing them to operate more efficiently with shorter separation times and lower energy consumption while still achieving thorough polymer removal
Solution Approach 2:
The settling tank performs a partial polymer removal action before the separation columns handle the remaining polymer. This staged approach divides the total removal task into two parts: bulk removal in the settling tank and final polishing in the separation columns, reducing overall separation time
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 significantly reduces energy costs and separation time by minimizing polymer content in separation streams, enhancing the efficiency of oligomer production and solvent reuse.
Implementation Method 1
layer separation into an upper layer liquid including the solvent and a lower layer liquid including the oligomer is performed in the settling tank
Implementation Method 2
removing a high-boiling point material from a lower discharge stream of the high-boiling point separation column
Implementation Method 3
separating a solvent and the oligomer in the solvent separation column
Data Source
Figure 1~2
Figure 3
AI summary
Provided is a method of producing an oligomer, the method including: supplying a monomer stream and a solvent stream to a reactor to perform an oligomerization reaction to produce a reaction product; supplying a discharge stream of the reactor to a separation device, and supplying an upper discharge stream of the separation device including an unreacted monomer to the reactor and supplying a lower discharge stream of the separation device to a settling tank; settling a polymer in the settling tank and removing the polymer, and supplying the lower discharge stream of the separation device from which the polymer is removed to a high-boiling point separation column; removing a high-boiling point material from a lower discharge stream of the high-boiling point separation column and supplying an upper discharge stream of the high-boiling point separation column including an oligomer to a solvent separation column; and separating a solvent and the oligomer in the solvent separation column.