Increasing Ethylene/Propylene Plant Product Yield via Multiple Phase Metathesis

75323-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 will construct a small continuous bench-scale unit and operate it to determine the specific process parameters needed for economic feasibility and for scale-up to a larger pilot plant. Commercial Applications and Other Benefits as described by the awardee: Nearly every U.S. ethylene plant should be able to cost-effectively utilize the multiple-phase metathesis process to reduce raw material consumption, reduce energy consumption, increase capacity, and enhance the profitability. In addition, the technology can be used to produce higher olefins at lower costs than the current process, which involves separate syntheses from ethylene or propylene. These higher olefins are used to make surfactants for laundry and industrial detergents, plasticizers used in the processing of plastics, and lubricants or lubricant additives used in motor oil and the drilling industry.