Staged Butane Hydrogenolysis Reactors for Thermal Runaway Mitigation
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Solution Overview
Problem
Butane hydrogenolysis processes face challenges in achieving high butane conversion and ethane selectivity while mitigating the risks of thermal runaway, which can be exacerbated by small fluctuations in reactor temperature.
Innovation Solution
A process involving a series of reactors with progressively increasing catalyst loading and reactor temperature rise, optionally with methane dilution, to stabilize the reaction and enhance butane conversion and ethane selectivity.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If the reactor temperature rise is increased to maximize butane conversion and ethane selectivity, then the reaction efficiency is improved, but the risk of thermal runaway increases
Solution Approach 1:
The patent divides the hydrogenolysis process into multiple reactors arranged in series (typically 3-5 reactors), with each reactor operating at a controlled temperature rise of 20-50°C. This segmentation allows the total temperature increase to be distributed across multiple stages, achieving high overall conversion while maintaining safe operating temperatures in each individual reactor, thus preventing thermal runaway.
Solution Approach 2:
The patent optimizes several parameters including hydrogen to butane molar ratio (0.3:1 to 0.8:1), reactor inlet temperature (200-300°C), and catalyst loading (increasing progressively from first to last reactor). These parameter changes enable high conversion and selectivity while maintaining thermal safety through controlled reaction conditions.
2Productivity
If the number of reactors in series is increased to improve butane conversion and ethane selectivity, then the reaction efficiency is improved, but the capital and operational costs increase
Solution Approach 1:
The patent employs a moderate number of reactors (3-5) rather than excessive numbers, achieving sufficient conversion (90%+) and selectivity (70%+) without incurring unnecessary capital and operational costs. This partial action approach balances performance requirements with economic constraints.
3Reliability
If the reactor inlet temperature is controlled to prevent thermal runaway, then the safety is improved, but the butane conversion and ethane selectivity may be compromised
Solution Approach 1:
The patent maintains continuous hydrogenolysis reaction across multiple reactors with controlled temperature rises, ensuring sustained high conversion and selectivity while preventing thermal runaway. The cumulative effect of multiple controlled reactions achieves the desired productivity without compromising safety.
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
The process effectively reduces the risk of thermal runaway and achieves high butane conversion and ethane selectivity, with the methane dilution further enhancing stability and efficiency.
Implementation Method 1
catalytic butane hydrogenolysis has been proposed to increase the yield and selectivity of high value hydrocarbon products such as ethane
Implementation Method 2
As butane hydrogenolysis involves highly exothermic reactions, the option of maximizing the reactor temperature rise may not be suitable, as beyond a point such reactor temperature rise may result in a thermal runaway
Data Source
AI summary
The invention relates to a process for butane hydrogenolysis for producing one or more desired hydrogenolysis products. The process involves introducing an initial feed stream comprising a butane feed and hydrogen feed in a reactor system comprising a number of reactors, for example not more than 10 reactors, arranged in a series. Each of these reactors contain a butane hydrogenolysis catalyst loaded at specific catalyst loading in a manner such that every reactor apart from the first reactor in the series has higher catalyst loading than the catalyst loading of the immediately preceding reactor. Further, each of the reactors are configured to operate at a higher reactor temperature rise than the preceding reactor. The process may include the use of diluent, preferably methane, with the feed stream in one or more of the reactors. The invention further relates to a reactor system process for conducting the process for butane hydrogenolysis.