Oxidative Dehydrogenation Catalyst for Ethylene Yield
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Solution Overview
Problem
Conventional steam cracking processes for producing ethylene are energy-intensive, produce unwanted byproducts, and require costly and complex furnaces, while oxidative dehydrogenation methods face challenges with low product selectivity and energy efficiency.
Innovation Solution
The method involves recycling methane and using an oxide-based redox catalyst in a circulating fluidized bed reactor or packed bed reactor system to enhance ethylene yield, reducing byproduct formation and energy consumption, and integrating with steam cracker separation trains to optimize ethylene production.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If conventional steam cracking is used to produce ethylene, then high ethylene production is achieved, but energy consumption is very high and CO2 emissions are significant
Solution Approach 1:
The patent applies oxidative dehydrogenation using oxygen as a strong oxidant to convert ethane to ethylene. This replaces the conventional steam cracking process which requires high temperatures (700-1000°C) and large energy input. The oxidation reaction provides the necessary energy for dehydrogenation, eliminating the need for external fuel and reducing CO2 emissions while maintaining high ethylene production rates
Solution Approach 2:
The patent replaces the mechanical thermal cracking system (furnaces, heat exchangers, quenching systems) with a chemical oxidation system using oxygen and catalysts. This substitution eliminates the need for complex furnace infrastructure and reduces energy consumption by using chemical energy from oxygen directly in the reaction rather than external thermal energy
2Productivity
If steam cracking is used to produce ethylene, then high ethylene yield is achieved, but complex separation steps are required to remove contaminants
Solution Approach 1:
The patent extracts and removes the source of contaminants by using selective oxidative dehydrogenation that primarily produces ethylene with minimal byproducts. The oxygen-selective catalyst system ensures that ethane is converted to ethylene without significant formation of CO, CO2, or other hydrocarbon byproducts, thereby eliminating the need for complex separation systems to remove these contaminants
3Use of energy by moving object
If oxidative dehydrogenation is used to produce ethylene, then energy efficiency is improved, but product selectivity is low and byproduct formation is high
Solution Approach 1:
The patent introduces oxygen as an intermediary substance that mediates the conversion of ethane to ethylene. The oxygen selectively reacts with ethane in the presence of the catalyst to produce ethylene and water, avoiding the formation of unwanted byproducts. This intermediary approach maintains high energy efficiency while achieving high product selectivity
Solution Approach 2:
The patent changes the reaction parameters from high-temperature thermal cracking to controlled oxidation conditions with specific oxygen concentrations and catalyst systems. These parameter changes enable selective ethylene formation while maintaining energy efficiency, as the oxidation reaction proceeds at lower temperatures with higher selectivity compared to thermal cracking
4Productivity
If steam cracking furnaces are used for ethylene production, then high ethylene output is achieved, but capital costs and maintenance requirements are very high
Solution Approach 1:
The patent replaces the expensive mechanical steam cracking furnace system with a simpler oxidation reactor system using oxygen and catalysts. This substitution eliminates the need for large capital-intensive furnaces, frequent decoking operations, and tube replacements, thereby reducing both capital costs and maintenance requirements while maintaining high ethylene output
Solution Approach 2:
The use of oxygen as a strong oxidant enables the reaction to proceed without the need for high-temperature furnaces. The oxidation reaction provides its own energy, eliminating the need for external fuel and complex furnace infrastructure, thereby significantly reducing capital costs and maintenance requirements associated with traditional steam cracking furnaces
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 increases ethylene yield and energy self-sufficiency, reduces byproduct emissions, and simplifies product separation, achieving higher ethylene selectivity and yield with reduced methane production and reactor costs.
Implementation Method 1
oxidative dehydrogenation (ODH) of ethane to form ethylene
Implementation Method 2
contacting the reactor feed stream with an oxide-based redox catalyst to produce the product stream
Implementation Method 3
circulating fluidized bed reactor
Data Source
AI summary
Methods and systems are provided for oxidative dehydrogenation of a hydrocarbon feed stream to produce a product stream with improved ethylene yield. The methods can include the steps of (i) combining a recycle stream with the feed stream to form a reactor feed stream, (ii) contacting the reactor feed stream with an oxide-based redox catalyst to produce the product stream comprising ethylene and one or more byproducts selected from the group consisting of methane, ethane, other byproducts, and mixtures thereof, and (iii) removing all or a part of the methane and ethane from the product stream to produce the recycle stream. Systems for the oxidative dehydrogenation (ODH) of a hydrocarbon feed stream are also provided to produce a product stream with improved ethylene yield. The systems and methods can include an oxide-based redox catalyst, such as Mg6MnO8, Cu6PbO8, and Ni6MnO8.