Oxidative Dehydrogenation with Catalytic Membrane Reactor
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Solution Overview
Problem
Current steam cracking methods for producing olefins are energy-intensive, produce significant greenhouse gases, and require expensive reactor materials and downstream separation units.
Innovation Solution
An integrated process combining oxidative dehydrogenation (ODH) of C2-C4 alkanes to C2-C4 alkenes with a catalytic membrane dehydrogenation reactor (CMDR) to separate hydrogen from the product stream, using mixed metal oxide catalysts and membranes containing group 4 or group 5 elements.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If steam cracking is used to produce olefins, then high conversion rates can be achieved, but energy consumption increases and greenhouse gas emissions are significant
Solution Approach 1:
The patent changes the fundamental reaction parameters by using oxidative dehydrogenation instead of steam cracking, operating at lower temperatures (300-500°C vs 700-1000°C) while using oxygen as the oxidizing agent rather than steam, thereby reducing energy consumption while maintaining olefin production efficiency
Solution Approach 2:
The patent converts the harmful effect of low-temperature dehydrogenation (equilibrium limitation) into a benefit by using oxidative dehydrogenation where oxygen continuously reacts with hydrogen to form water, shifting the equilibrium toward olefin production and enabling high conversion rates at lower temperatures
2Productivity
If steam cracking is used to produce olefins, then high conversion rates can be achieved, but the process requires expensive reactor materials and downstream separation units
Solution Approach 1:
The patent changes the operating temperature parameter to below 500°C, which eliminates the need for expensive high-temperature reactor materials, and changes the chemical environment by using oxidative dehydrogenation instead of steam cracking, simplifying downstream separation requirements
Solution Approach 2:
The patent extracts and removes the complex downstream separation units and high-temperature reactor requirements from the process by using oxidative dehydrogenation, which produces a simpler product stream that requires less extensive separation and purification
3Duration of action of stationary object
If steam cracking is used to produce olefins, then the process can operate continuously, but coke production requires periodic shutdown for cleaning and maintenance
Solution Approach 1:
The patent converts the harmful coke formation into a beneficial process by using oxidative dehydrogenation where oxygen prevents coke deposition on catalyst surfaces, and any carbon deposits that do form are automatically oxidized and removed, enabling continuous operation without shutdowns for cleaning
Solution Approach 2:
The patent ensures continuous operation by using oxidative dehydrogenation that prevents coke accumulation, allowing the catalyst to maintain its activity continuously without periodic regeneration or cleaning shutdowns that are required in steam cracking processes
4Manufacturing precision
If ODH is used to produce ethylene with high selectivity, then around 98% selectivity can be achieved, but the process requires better catalyst development and safety measures against thermal runaway
Solution Approach 1:
The patent implements feedback control by using oxygen as a reactant that can be precisely controlled and monitored, allowing the reaction to be kept within safe operating parameters while maintaining high ethylene selectivity through optimized oxygen-to-alkane ratios and catalyst design
Solution Approach 2:
The patent changes the reaction parameters by using oxidative dehydrogenation with controlled oxygen addition, which provides inherent safety through the exothermic nature of the reaction that can be easily controlled, and achieves high ethylene selectivity through optimized catalyst composition and reaction conditions
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 operates at lower temperatures, reduces greenhouse gas emissions, eliminates coke production, and achieves high selectivity for ethylene (around 98%) with improved economic benefits and safety compared to traditional steam cracking methods.
Implementation Method 1
contacting in an oxidative dehydrogenation process a feed including at least one C2-C4 alkane and oxygen with at least one mixed metal oxide catalyst to produce a product stream which includes unreacted C2-C4 alkane and one or more corresponding C2-C4 alkenes
Implementation Method 2
passing the product stream to a catalytic membrane dehydrogenation reactor process including at least one membrane containing one or more group 4 elements or group 5 elements to dehydrogenate at least a portion of the unreacted C2-C4 alkane to produce at least one permeate stream that includes hydrogen and at least one retentate stream which includes one or more corresponding C2-C4 alkenes that is substantially free of hydrogen
Implementation Method 3
dehydrogenate at least a portion of the unreacted C2-C4 alkane to produce at least one permeate stream that includes hydrogen and at least one retentate stream which includes one or more corresponding C2-C4 alkenes
Data Source
AI summary
This disclosure relates to a process of converting one or more alkanes to one or more alkenes that includes providing a first stream containing one or more alkanes and oxygen to an oxidative dehydrogenation process which converts at least a portion of the one or more alkanes to one or more alkenes in an oxidative dehydrogenation reactor, a second stream exiting the oxidative dehydrogenation process comprising one or more alkanes, and one or more alkenes; and providing at least a portion of the alkanes in the second stream to a catalytic membrane dehydrogenation process containing a catalyst loaded into a catalytic dehydrogenation membrane reactor which converts at least a portion of the alkanes to the corresponding alkenes and hydrogen.