Increasing Ethylene/Propylene Plant Product Yield via Three Phase Metathesis

75323B Ethylene is the largest volume petrochemical in the world ¿ some 40 large scale plants operate in the United States alone. Ethylene production is energy-intensive and non-selective, with a number of heavier, lower value products being made. As the price of energy in North America increases, the U.S. ethylene industry becomes less competitive compared to foreign producers. This project will develop multiple-phase metathesis technology, a reactive distillation application that will increase the yield of ethylene and propylene from ethylene plants. The process works by converting a large portion of the heavier, low value by-products to ethylene, propylene, and downstream derivatives of ethylene in a single step, thereby reducing both raw material and energy consumption per unit of product made. Phase I investigated catalyst life and defined design parameters. The catalyst life cycle was determined in a 30-day test run. The design parameters included the maximum throughput rate and the optimal feed location, both of which were identified during another 30-day test. A reactive-distillation simulation was developed and confirmed by comparison with pilot plant results. In Phase II, a semi-commercial pilot plant will be built and operated to confirm the design parameters. Pail, drum, and truck-load quantities of ethylene samples will be made, and the feasibility of making high value, heavier specialty products will be investigated. Commercial Applications and Other Benefits as described by the awardee: Nearly every ethylene plant in the United States should be able to utilize the multiple-phase metathesis process to reduce raw material consumption, reduce energy consumption, increase capacity, and enhance profitability. In addition, the technology could be used to make higher olefins, which are currently made via separate step from ethylene or propylene. The derivatives could be used to make surfactants for laundry and industrial detergents, plasticizers for the processing of plastics, and lubricants or lubricant additives for the motor oil and drilling industries.