Turbulent Fluidized-Bed Reactor for Propene and C4 Hydrocarbon Production
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Solution Overview
Problem
Current methods for producing propylene and C4 hydrocarbons from methanol suffer from low reaction rates of ethylene alkylation, leading to inefficient unit volume production capacity and catalyst deactivation due to carbon deposition, which inhibits the alkylation of olefins.
Innovation Solution
A turbulent fluidized-bed reactor design is implemented, featuring a reaction zone with multiple feed distributors for uniform oxygen-containing compound distribution and a regenerator for catalyst regeneration, enhancing catalyst activity and reducing carbon deposition, thereby increasing the alkylation reaction rate and propylene and C4 hydrocarbon yield.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If methanol-to-olefin reaction is carried out using acidic molecular sieve catalyst, then propylene and C4 hydrocarbons are produced, but carbon deposition occurs on the catalyst leading to decreased activity and inhibited alkylation of olefins
Solution Approach 1:
The reactor is divided into multiple reaction zones with feed distributors positioned at different heights, creating segmented reaction environments that control carbon deposition and maintain catalyst activity in different zones
Solution Approach 2:
Oxygen-containing compounds are distributed uniformly before entering the reaction zone through multiple feed distributors, preventing excessive carbon deposition before it occurs and maintaining catalyst activity
2Manufacturing precision
If light fractions are recycled to increase alkylation reaction, then propylene and C4 hydrocarbon selectivity is improved, but unit volume production capacity decreases due to high light fraction content
Solution Approach 1:
The reactor is segmented into multiple zones with feed distributors at different positions, creating controlled reaction environments that improve conversion efficiency and reduce light fraction content while maintaining selectivity
Solution Approach 2:
Reaction parameters are optimized through controlled oxygen-containing compound distribution, changing the reaction conditions to improve conversion efficiency and reduce light fraction content in the product gas
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 turbulent fluidized-bed reactor design significantly improves the alkylation reaction rate of olefins, resulting in higher propylene and C4 hydrocarbon yields with reduced light fractions in the product gas, increasing the unit volume production capacity and maintaining catalyst activity.
Implementation Method 1
a turbulent fluidized-bed reactor design is implemented, featuring a reaction zone with multiple feed distributors for uniform oxygen-containing compound distribution and a regenerator for catalyst regeneration
Implementation Method 2
a regenerator for catalyst regeneration, enhancing catalyst activity and reducing carbon deposition
Data Source
Figure 1
AI summary
The present invention refers to a turbulent fluidized-bed reactor, device and method for preparing propylene and C4 hydrocarbons from oxygen-containing compounds. The device comprises the turbulent fluidized-bed reactor and a fluidized-bed regenerator for regenerating a catalyst. The method includes: a) feeding a raw material containing the oxygen-containing compounds from n reactor feed distributors to a reaction zone of the turbulent fluidized-bed reactor, and contacting the raw material with a catalyst, to generate a stream containing target product and a spent catalyst containing carbon; b) sending the stream discharged from the turbulent fluidized-bed reactor containing target product into a product separation system, obtaining propylene, C4 hydrocarbons, light fractions and the like after separation, returning 70 wt.% or more of the light fractions to the reaction zone of the turbulent fluidized-bed reactor from the reactor feed distributor at the bottom-most of the turbulent fluidized-bed reactor, and reacting ethylene and the oxygen-containing compounds to perform an alkylation reaction in presence of the catalyst, to produce products of propylene and the like. The method and device of the present invention improve the reaction rate of ethylene alkylation, and the unit volume production capacity of reactor is high.