Silane Purification via Ethylene Conversion Before Distillation
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Solution Overview
Problem
Current silane purification processes are complex and energy-intensive, requiring significant heating and cooling, and do not achieve high silane purity and recovery rates effectively.
Innovation Solution
A process and system that convert ethylene in silane-containing streams to ethylsilane and ethane prior to distillation, using a reactor with catalysts like zeolite-supported platinum or nickel, followed by light-ends and heavy-ends distillation columns to produce a silane-enriched and depleted fractions, reducing energy transfer and simplifying the purification process.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If conventional purification processes are used, then silane can be purified, but the process complexity and energy consumption increase significantly
Solution Approach 1:
The patent applies preliminary action by converting ethylene to ethylsilane and ethane in a reactor before the distillation process. This pre-treatment step modifies the impurity composition to facilitate easier and more efficient separation in subsequent distillation columns, reducing overall process complexity while achieving high purity
2Manufacturing precision
If conventional purification processes are used, then silane can be purified, but energy consumption increases significantly
Solution Approach 1:
The patent employs parameter changes by optimizing distillation column operating conditions (temperature, pressure, reflux ratios) and reactor conditions to achieve efficient separation and conversion. These optimized parameters reduce energy consumption while maintaining high silane purity recovery rates
3Manufacturing precision
If conventional purification processes are used, then impurities can be removed, but the process requires significant heating and cooling
Solution Approach 1:
The patent implements continuity of useful action through integrated heat exchange networks between process streams. Heat from exothermic reactions and hot process streams is continuously transferred to preheat feed streams, maintaining continuous useful thermal action and minimizing heating and cooling energy losses
4Manufacturing precision
If conventional purification processes are used, then silane can be purified, but the recovery rate is reduced
Solution Approach 1:
By converting ethylene to ethylsilane and ethane before distillation, the preliminary reaction step prevents ethylene from co-distilling with silane in light-ends column, enabling better separation and higher silane recovery in the purified product stream
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 achieves high silane purity and recovery rates with a simpler design, reducing energy input and output, and allows for efficient separation of impurities, thereby improving the overall efficiency of silane purification.
Implementation Method 1
A process and system that convert ethylene in silane-containing streams to ethylsilane and ethane prior to distillation, using a reactor with catalysts like zeolite-supported platinum or nickel
Implementation Method 2
The ethylene-depleted stream is introduced into a light-ends distillation column to produce a silane-depleted overhead fraction and a silane-enriched bottoms fraction relative to the ethylene-depleted stream
Data Source
AI summary
Processes and systems for purifying silane-containing streams and, in particular, for purifying silane-containing streams that also contain ethylene are disclosed. The processes and systems may be arranged such that one or more ethylene reactors are downstream of light-end distillation operations.