Qualifying Abrasive Materials for Alkylene Oxide Reactor Cleaning
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Solution Overview
Problem
The existing cleaning processes for alkylene oxide reactors introduce impurities due to rust formation and the use of unqualified abrasive materials, which can lead to sub-optimal end-products and process inefficiencies.
Innovation Solution
A method to qualify abrasive blasting materials by determining the pre- and post-contact amounts of alkylene oxide by-products with a feed stream, ensuring that the materials do not contribute to the formation of by-products, thereby preventing impurity introduction during the cleaning process.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If abrasive material is used to clean the inner surfaces of reactor tubes, then rust formation is prevented, but impurities are introduced into the process
Solution Approach 1:
The abrasive material is tested beforehand by contacting it with alkylene oxide feedstock to determine if it produces harmful by-products. Only materials that pass this preliminary qualification test are approved for use in the reactor tubes, preventing impurity introduction while maintaining rust prevention benefits
Solution Approach 2:
The invention uses disposable abrasive blasting material that is applied and then removed. The material is qualified beforehand to ensure it doesn't leave harmful residues, and any residual material is purged from the system, allowing the use of effective abrasive materials without long-term contamination concerns
2Manufacturing precision
If cleaning material is not completely removed after cleaning, then cleaning effectiveness is maintained, but by-products are formed during alkylene oxide production
Solution Approach 1:
The abrasive material undergoes preliminary qualification testing by contacting it with alkylene oxide feedstock to identify materials that do not produce harmful by-products. This pre-screening ensures that even if residual material remains after cleaning, it will not contaminate the product
Solution Approach 2:
The testing method provides feedback on the suitability of abrasive materials by measuring by-product formation. This feedback loop allows selection of materials that maintain cleaning effectiveness while preventing harmful by-product formation during subsequent production cycles
Data Source
AI summary
The present invention relates to methods for qualifying material for using in the cleaning of alkylene oxide equipment. Qualified material is not expected to contribute to the formation of determinable amounts of alkylene oxide by-products. Methods of cleaning alkylene oxide equipment, and alkylene oxide processes incorporating these methods are also provided.