Integrated Propane Dehydrogenation and Alkylation Process

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Solution Overview

Problem

Conventional propane dehydrogenation and cumene production processes face high energy consumption due to the need for heat pumps and refrigeration, with inefficient use of waste heat and propane recycling processes.

Innovation Solution

Integrating a propane dehydrogenation unit with an alkylation unit, utilizing low-pressure steam from the alkylation process as a heat source for the dehydrogenation unit and recycling propane directly from the cumene unit to the dehydrogenation unit without pressurization or liquefaction, reducing energy consumption by leveraging waste heat and eliminating the need for refrigeration.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Manufacturing precision

If a low pressure product splitter is used in propane dehydrogenation, then polymer grade propylene can be produced, but a heat pump is required which increases operating costs

Engineering Contradiction:

Improvepropylene purityVSAvoidheat pump operating cost

Core Design Contradiction:

Manufacturing precisionVSUse of energy by moving object

Solution Approach 1:

The patent combines the propane dehydrogenation unit with the alkylation unit into an integrated process. The low-pressure steam generated from the alkylation reaction zone is directly utilized to provide heating for the dehydrogenation reaction zone, eliminating the need for separate heat pump systems and reducing operating costs while maintaining propylene production efficiency

Inventive Principle:

Principle #5Merging (Combining)

2Use of energy by moving object

If a high pressure product splitter is used in propane dehydrogenation, then no heat pump is required, but an external heat source is still needed to operate

Engineering Contradiction:

Improveheat pump requirementVSAvoidexternal heat source requirement

Core Design Contradiction:

Use of energy by moving objectVSUse of energy by stationary object

Solution Approach 1:

The integrated process enables self-service by using the low-pressure steam generated internally from the alkylation reaction zone to provide the necessary heating for the dehydrogenation reaction zone. This eliminates the need for external heat sources and creates a self-sufficient thermal system

Inventive Principle:

Principle #25Self-service

3Loss of substance

If propane is recycled from cumene production, then refrigeration and liquefaction are required which increase energy consumption

Engineering Contradiction:

Improvepropane recoveryVSAvoidrefrigeration and liquefaction energy

Core Design Contradiction:

Loss of substanceVSUse of energy by moving object

Solution Approach 1:

The patent changes the operational parameters of the integrated system such that propane is recycled directly from the alkylation unit to the dehydrogenation unit without requiring refrigeration or liquefaction. The propane stream is utilized in its existing state, eliminating energy-intensive phase change operations

Inventive Principle:

Principle #35Parameter changes

4Loss of energy

If low pressure steam is rejected to air or cooling water in cumene production, then heat is wasted, but the steam system cannot utilize it

Engineering Contradiction:

Improveheat rejectionVSAvoidsteam system compatibility

Core Design Contradiction:

Loss of energyVSAdaptability or versatility

Solution Approach 1:

The patent merges the cumene production steam system with the propane dehydrogenation process by routing the low-pressure steam that would otherwise be rejected to air or cooling water directly to the dehydrogenation reaction zone for heating. This integration eliminates heat waste and creates mutual benefit between the two processes

Inventive Principle:

Principle #5Merging (Combining)

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 integration significantly reduces energy costs by utilizing waste heat and eliminating the need for refrigeration and liquefaction, resulting in substantial operating cost savings and improved energy efficiency in both propane dehydrogenation and cumene production.

Implementation Method 1

the propylene is reacted with benzene to produce an alkylated product and generate a low pressure steam

Methodology Applied

Scientific EffectExothermic reaction: Exothermic Reaction

Implementation Method 2

the propylene is separated in a separation system to form a polymer-grade propylene stream, a low purity propylene stream, and a propane stream

Methodology Applied

Scientific EffectDistillation: Distillation

Implementation Method 3

The low pressure steam may then be fed to the separation system as a heat source

Methodology Applied

Scientific EffectHeat exchange: Heat Exchanger

Implementation Method 4

a hydrocarbon feedstock containing propane is fed to a propane dehydrogenation reaction zone to convert a portion of the propane to propylene

Methodology Applied

Scientific EffectEndothermic reaction: Endothermic Reaction

Data Source

PatentUS10450241B2Integrated propane dehydrogenation process

Publication Date: 2019.10.22 LUMMUS TECHNOLOGY INC

AI summary

Processes and systems for the integrated production of propylene and an alkylate, such as cumene, may include feeding a hydrocarbon feedstock containing propane to a propane dehydrogenation reaction zone to convert a portion of the propane to propylene. The propylene is separated in a separation system to form a polymer-grade propylene stream, a low purity propylene stream, and a propane stream. The low purity propylene stream is then fed to an alkylation reaction zone where the propylene is reacted to produce an alkylated product and generate a low pressure steam. The low pressure steam may then be fed to the separation system as a heat source, integrating the dehydrogenation system and the alkylation system.