Single Reactor System for Sequential Light Olefin Production
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Solution Overview
Problem
The existing chemical processing technologies lack a flexible reactor system capable of efficiently handling multiple types of reactions, such as dehydrogenation, cracking, dehydration, and methanol-to-olefin reactions, using different feed streams without the need for separate reactor systems.
Innovation Solution
A method and reactor system design that allows for the sequential processing of two different chemical feed streams in a single reactor, utilizing different catalysts and reaction types for each stream, with the reactor sections configured to operate as fast fluidized, turbulent, or bubbling bed reactors and dilute phase riser reactors.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If separate reactor systems are used for each reaction type (dehydrogenation, cracking, dehydration, methanol-to-olefin), then each reaction can be optimized for its specific feed stream, but capital costs increase and system complexity increases
Solution Approach 1:
The reactor system is designed to perform multiple reaction types (dehydrogenation, cracking, dehydration, and methanol-to-olefin reactions) within a single integrated unit. The reactor can be configured with different catalysts and operating conditions to handle various feed streams, eliminating the need for separate dedicated reactors for each reaction type while maintaining optimization for each specific process
2Adaptability or versatility
If separate reactor systems are used for each reaction type, then reaction optimization is improved, but capital costs increase
Solution Approach 1:
Multiple reactor systems that would traditionally be required for different reaction types are merged into a single integrated reactor system. This consolidation reduces capital costs by eliminating redundant equipment while maintaining the ability to perform each reaction type with appropriate catalysts and operating conditions
3Ease of manufacture
If a single reactor system handles multiple reaction types, then capital costs are reduced, but the reactor design complexity increases
Solution Approach 1:
The reactor system incorporates dynamic configurability through removable and replaceable catalyst cartridges, allowing the reactor design to adapt to different reaction requirements. This dynamic element enables a single reactor structure to handle multiple reaction types by simply changing the catalyst configuration, rather than requiring complex fixed designs for each reaction type
4Productivity
If different catalysts are used for different feed streams, then reaction efficiency is improved, but system complexity increases
Solution Approach 1:
The catalyst system is segmented into separate removable cartridges, each optimized for specific reaction types. This segmentation allows efficient catalyst management by enabling independent replacement and optimization of each catalyst unit without affecting the entire system, thereby maintaining high reaction efficiency while simplifying catalyst management procedures
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 reduces capital costs by eliminating the need for separate reactor systems and allows for the selection of the most economical feed stream and reaction type, while maintaining high efficiency in producing light olefins.
Implementation Method 1
contacting a first feed stream with a first catalyst in a reactor, wherein the contacting of the first feed stream with the first catalyst causes a first reaction which forms a first product stream
Implementation Method 2
contacting a second feed stream with a second catalyst in the reactor, wherein the contacting of the second feed stream with the second catalyst causes a second reaction which forms a second product stream
Implementation Method 3
the reactor comprises an upstream reactor section operating as a fast fluidized, turbulent, or bubbling bed reactor
Data Source
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AI summary
According to one or more embodiments of the present disclosure, chemical streams may be processed by a method which may comprise operating a first chemical process, stopping the first chemical process and removing the first catalyst from the reactor, and operating a second chemical process. The reaction of the first chemical process may be a dehydrogenation reaction, a cracking reaction, a dehydration reaction, or a methanol-to-olefin reaction. The reaction of the second chemical process may be a dehydrogenation reaction, a cracking reaction, a dehydration reaction, or a methanol-to-olefin reaction. The first reaction and the second reaction may be different types of reactions.