Single Bed Purification of Lower Olefins
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Solution Overview
Problem
Conventional methods for purifying ethylene monomers require multiple beds and specific catalysts or adsorbents, leading to high capital and operating costs, as well as extended processing times, due to the need for sequential removal of trace contaminants which are highly sensitive and affect polyethylene production yield.
Innovation Solution
A single bed of materials comprising copper catalysts with promoters and porous inorganic oxide supports is used to remove a broad range of contaminants, including CO, O2, CO2, acetylene, H2, H2O, and sulfur compounds, down to ppb levels, operating under a single process condition, which can be regenerated and reused.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If multiple beds with specific catalysts or adsorbents are used to remove individual contaminants sequentially, then the removal effectiveness of trace contaminants is improved, but the capital costs, operating costs, and processing time increase substantially
Solution Approach 1:
The patent combines multiple catalysts and adsorbents that were previously used in separate beds into a single integrated bed. This single bed contains a composite material comprising copper-based catalyst particles dispersed on a porous support, which can simultaneously remove multiple contaminants (CO, CO2, O2, acetylene, H2S, H2O) that previously required sequential treatment in multiple beds, thereby reducing device complexity while maintaining removal effectiveness
Solution Approach 2:
The single bed material is designed to perform multiple purification functions simultaneously. The copper-based catalyst and porous support combination provides universal contaminant removal capability across different contaminant types (gases, liquids, trace impurities) under a single process condition, eliminating the need for multiple specialized beds and reducing overall system complexity
2Manufacturing precision
If multiple beds are used for sequential contaminant removal, then the purity level of ethylene monomer is improved, but the processing time and operating costs increase
Solution Approach 1:
The single bed enables continuous simultaneous removal of all contaminants in one pass through the bed, eliminating the sequential step-by-step process of multiple beds. The feed stream passes through the single bed once and emerges purified, maintaining continuous operation without the time losses associated with multiple sequential treatment stages, thus achieving high purity while reducing processing time
3Adaptability or versatility
If multiple beds with different catalysts are used, then the broad range of contaminants can be removed, but the capital costs and equipment requirements increase
Solution Approach 1:
The patent employs a composite material system within a single bed, combining copper-based catalyst particles (providing catalytic activity for various contaminant removal reactions) dispersed on a porous support material (提供ing surface area and structural stability). This composite structure integrates the functionalities of multiple different catalysts and adsorbents into one material system, achieving broad contaminant removal versatility while eliminating the need for multiple separate equipment units
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 reduces production costs and time by achieving >99% removal of contaminants in a single step, enhancing catalytic productivity and monomer purity, while maintaining efficiency across varying temperatures and flow rates.
Implementation Method 1
a bed of materials comprising copper catalysts with optionally one or more promoters and a support
Implementation Method 2
porous inorganic oxide supports
Data Source
AI summary
Disclosed herein are a bed of materials and use of it for removing contaminants not limiting to carbon monoxide, oxygen, carbon dioxide, acetylene, hydrogen, water, carbonyl sulfide and hydrogen sulfide from lower olefins without limiting ethylene.