Single-Vessel Feed Fluid Purification at Ambient Temperature
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Existing polymerization catalysts are sensitive to impurities such as oxygen, carbon monoxide, and water, which require high-temperature purification processes, leading to increased energy consumption and production costs.
Innovation Solution
A method for removing impurities like carbon monoxide, oxygen, and water from feed fluids at ambient temperatures using a reduced copper-based material and adsorbents in a single vessel, allowing for simultaneous purification of ethylene in a single vessel at or near ambient temperatures.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If high-temperature purification processes are used to remove impurities from feed streams, then impurity removal effectiveness is improved, but energy consumption increases
Solution Approach 1:
The patent changes the operating temperature parameter from high temperature (conventional) to ambient temperature (invention), while achieving equivalent or superior impurity removal effectiveness. This is accomplished through the use of a specifically formulated catalyst composition that is active at ambient temperatures, thereby resolving the contradiction between effectiveness and energy consumption.
Solution Approach 2:
The patent replaces the thermal energy input system (heating equipment) with a catalytic chemical system. Instead of using heat to drive impurity removal reactions, the invention uses catalysts to enable the reactions to proceed at ambient temperatures, substituting a mechanical/thermal system with a chemical catalytic system.
2Reliability
If multiple purification stages are used to remove different impurities, then purification completeness is improved, but device complexity increases
Solution Approach 1:
The patent merges multiple purification functions (removal of oxygen, carbon monoxide, water, and other impurities) into a single purification stage. The catalyst composition contains multiple active components that work simultaneously to remove different types of impurities, eliminating the need for separate purification stages for each impurity type.
Solution Approach 2:
The catalyst composition is designed with multi-functionality, where a single catalyst bed performs multiple purification tasks. The catalyst contains components that can remove oxygen, carbon monoxide, water, and other impurities simultaneously, making one purification stage universal for handling multiple impurity types that would otherwise require separate stages.
3Productivity
If heating and cooling steps are added to the purification process, then impurity removal efficiency is improved, but capital expenses increase
Solution Approach 1:
The patent extracts the heating and cooling steps from the purification process, eliminating the need for heat exchangers, heaters, and associated control systems. By designing a catalyst that operates at ambient temperature, the invention removes these capital-intensive equipment components while maintaining impurity removal efficiency.
Solution Approach 2:
The purification process is designed to be self-service at ambient conditions, using the natural temperature of the feed stream without requiring external heating or cooling. The catalyst composition is specifically formulated to be active at ambient temperatures, allowing the process to utilize the existing thermal state of the feed rather than requiring energy input or output equipment.
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
Achieves efficient removal of impurities to levels below 0.2 ppm by volume without the need for pre-heating or cooling, reducing capital and operating expenses by eliminating the requirement for additional purification stages.
Implementation Method 1
Copper (Cu) in its various oxidation states, particularly copper oxide (CuO), is useful for removing certain poisons, such as carbon monoxide, through catalytic oxidation of carbon monoxide to carbon dioxide (CO 2 )
Implementation Method 2
the oxidation of carbon monoxide by copper oxide is typically accomplished at temperatures well above ambient temperature to effectively remove the carbon monoxide
Implementation Method 3
a vessel having an adsorbent bed(s) for removal of water and carbon dioxide
Data Source
Figure 1~2
Figure 3~4
Figure 5
AI summary
Systems and methods for removing impurities from a feed fluid in a single vessel. A method generally includes, in a single vessel, contacting a feed fluid passing through the vessel with a copper-based material for removing oxygen from the feed fluid; and contacting the feed fluid passing through the vessel with an adsorbent for removing at least one of water, carbon dioxide, and oxygenated hydrocarbons from the feed fluid.