Reactive Distillation with Side Reactors for Olefin Conversion
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Solution Overview
Problem
Metathesis reactions in olefin production are equilibrium limited, making it difficult to achieve complete conversion in a single reactor stage, and existing reactive distillation processes face complexities in design and development, limiting the efficient production of high-value olefins like propylene and 1-hexene.
Innovation Solution
An integrated reactive distillation column with reactive pump-arounds and external side reactors, specifically plug flow reactors, is used to enhance metathesis reactions, allowing for on-demand synthesis of olefins by continuously removing products and maintaining favorable reaction conditions.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If reactive distillation is used to enhance metathesis reaction yields, then product conversion is improved, but process development complexity increases
Solution Approach 1:
The reactive distillation process is segmented into multiple stages with side reactors positioned at specific stages of the distillation column. This allows the complex reaction-separation process to be divided into manageable segments, each optimized for specific conversion requirements while maintaining overall process integration.
Solution Approach 2:
Side reactors are introduced as intermediary units that facilitate the metathesis reaction at specific points in the distillation column. These intermediary reactors enable enhanced conversion by providing dedicated reaction zones while the distillation column handles separation, thus managing the complexity through functional specialization.
2Device complexity
If a single stage reactor is used for metathesis reaction, then device complexity is reduced, but reaction conversion is limited due to equilibrium constraints
Solution Approach 1:
The invention merges reaction and distillation operations into an integrated reactive distillation system. By combining the single-stage simplicity with multi-stage reaction-separation integration, the system achieves high conversion without requiring multiple independent reactors, thus maintaining relative simplicity while overcoming equilibrium limitations.
Solution Approach 2:
The reactive distillation column operates continuously with simultaneous reaction and separation occurring throughout the column height. This continuous action allows the system to constantly remove products and supply reactants, maintaining favorable equilibrium conditions and achieving high conversion in a single integrated unit rather than requiring multiple sequential stages.
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 increases the total conversion of C4 olefins from 33.3% to 82.2% (or 60.7% to 95.3%) in standalone and reactive pump-around processes respectively, improving the efficiency and versatility of olefin production.
Implementation Method 1
distilling a distillation column feed stream in a distillation column
Implementation Method 2
contacting, in a pre-distillation reactor, reactants of a feed stream in the presence of a catalyst and thereby carrying out a metathesis reaction
Data Source
AI summary
Systems and methods for carrying out metathesis reaction by utilizing one or more side reactors to a reactive distillation column is disclosed. The one or more side reactors is used to effect a reactive pump-around process. The systems and methods are used for equilibrium limited reactions such as the metathesis of C4 olefins.