阅读说明：本技术 环氧烷分离系统 (Alkylene oxide separation system ) 是由 E·I·罗斯-梅德戈德 D·W·莱申 K·P·鲁芬内尔 S·康卡基蒂苏普查 R·J·沃尔夫 于 2019-02-05 设计创作，主要内容包括：一种环氧丙烷分离系统,包括重质蒸馏塔和第一萃取蒸馏塔,重质蒸馏塔被配置为接收粗氧化丙烯流并排出重质清洗塔底物,重质清洗塔底物包含选自丙酮、甲醇、醛衍生物、水、包含C<Sub>5</Sub>+的重质烃或其组合的至少一种杂质,并排出包含与粗氧化丙烯流一起进入的大部分环氧丙烷的重质蒸馏塔塔顶流,第一萃取蒸馏塔被配置为接收重质蒸馏塔塔顶流和包含烃溶剂的第一萃取溶剂流,并排出包含选自醛(例如乙醛、甲醛等)、甲酸甲酯、甲醇、水、C<Sub>3</Sub>烃、C<Sub>4</Sub>烃或其组合的至少一种杂质的轻质清洗塔顶流,并排出包含经由重质蒸馏塔塔顶流进入的大部分环氧丙烷的富溶剂塔底流。还提供了一种环氧丙烷纯化方法。(An epoxypropane separation system comprises a heavy distillation column and a first extractive distillation column, the heavy distillation column is configured to receive a crude propylene oxide stream and discharge a heavy purge bottoms, the heavy purge bottoms comprises a component selected from the group consisting of acetone, methanol, aldehyde derivatives, water, C, and mixtures thereof 5 + a heavy hydrocarbon or a combination thereof, and withdrawing a heavy distillation column overhead stream comprising a majority of the propylene oxide entering with the crude propylene oxide stream, the first extractive distillation column being configured to receive the heavy distillation column overhead stream and a first extractive solvent stream comprising a hydrocarbon solvent, and withdrawing a heavy distillation column overhead stream comprising at least one impurity selected from aldehydes (e.g., acetaldehyde, formaldehyde, etc.), methyl formate, methanol, water, C, and mixtures thereof 3 Hydrocarbons, C 4 At least one hetero atom of a hydrocarbon or combination thereofA light, heavy purge overhead stream and a solvent-rich bottoms stream comprising a major portion of the propylene oxide entering via the heavy distillation overhead stream. A process for purifying propylene oxide is also provided.)

1. A propylene oxide separation system comprising:

A) a heavy distillation column configured to receive a crude propylene oxide stream and discharge:

a1) heavy purge bottoms comprising a compound selected from the group consisting of acetone, methanol, aldehydes, aldehyde derivatives, water, C₅+ a heavy hydrocarbon or a combination thereof, and

a2) a heavy distillation column overhead stream comprising a major portion of the propylene oxide entering with the crude propylene oxide stream; and

B) a first extractive distillation column configured to receive the heavy distillation column overhead stream and a first extractive solvent stream comprising a hydrocarbon solvent and to discharge:

b1) a light wash overhead comprising at least one impurity selected from acetaldehyde, methyl formate, methanol, water, a C3 hydrocarbon, a C4 hydrocarbon, or a combination thereof, and

b2) a rich solvent bottoms stream comprising a majority of the propylene oxide entering via the heavy distillation column overhead stream.

2. The propylene oxide separation system of claim 1, wherein the first extractive distillation column is further configured to discharge a side extract, and wherein the propylene oxide separation system further comprises a decanter configured to receive the side extract, a hydrocarbon-lean solvent stream comprising the hydrocarbon solvent, and optionally water, allow formation of an aqueous phase and an organic phase, discharge an aqueous phase purge comprising water and methanol, one or more glycols, or a combination thereof, and discharge an organic phase stream comprising propylene oxide and the hydrocarbon solvent.

3. A propylene oxide separation system according to claim 2, further comprising a first solvent stripper configured to receive a rich solvent bottoms stream from the first extractive distillation column, discharge a first solvent stripper overhead comprising a majority of the propylene oxide entering with the rich solvent bottoms stream, and discharge a first solvent stripper bottoms comprising a lean hydrocarbon solvent.

4. A propylene oxide separation system as recited in claim 3, wherein the first extractive distillation column is fluidly connected to the first solvent stripper column, whereby at least a portion of the lean hydrocarbon solvent from the first solvent stripper column bottoms can be introduced into the first extractive distillation column via the first extractive solvent stream.

5. The propylene oxide separation system of claim 3, further comprising:

a second extractive distillation column configured to receive the first solvent stripper overhead and a second extractive solvent stream comprising the hydrocarbon solvent, to discharge an overhead propylene oxide product stream comprising a majority of the propylene oxide from the first solvent stripper overhead, and to discharge a second extractive distillation column bottoms comprising a hydrocarbon-rich solvent; and

a second solvent stripper configured to receive the second extractive distillation bottoms, discharge a hydrocarbon purge overhead stream, and discharge a second solvent stripper bottoms comprising a lean hydrocarbon solvent.

6. The propylene oxide separation system of claim 5, wherein the second solvent stripper is fluidly coupled to the first extractive distillation column, the decanter, or both, whereby a portion of the lean hydrocarbon solvent from the second solvent stripper bottoms can be introduced into the first extractive distillation column, the decanter, or both.

7. A propylene oxide separation system as recited in claim 5, wherein the second solvent stripper is fluidly coupled to the second extractive distillation column whereby at least a portion of the lean hydrocarbon solvent from the second solvent stripper bottoms can be introduced into the second extractive distillation column via the second extractive solvent stream.

8. The propylene oxide separation system of claim 1, which does not comprise a non-solvent distillation column upstream of the first extractive distillation column other than the heavies distillation column.

9. The propylene oxide separation system of claim 1, further comprising:

a decanter configured to receive at least a portion of the light wash overhead, a hydrocarbon solvent-lean stream comprising a hydrocarbon solvent, and optionally water, allow formation of an aqueous phase and an organic phase, and discharge an aqueous phase purge comprising water and methanol, one or more glycols, or a combination thereof, and discharge an organic phase stream comprising propylene oxide and the hydrocarbon solvent back to the first extractive distillation column.

10. The propylene oxide separation system of claim 1, further comprising:

a decanter configured to receive at least a portion of the light wash overhead, a hydrocarbon solvent-lean stream comprising a hydrocarbon solvent, and optionally water, allow formation of an aqueous phase and an organic phase, discharge an aqueous phase purge comprising water and methanol, one or more glycols, or a combination thereof, and discharge an organic phase stream comprising propylene oxide and the hydrocarbon solvent; and

a solvent stripper configured to receive the organic phase stream from the decanter, discharge a hydrocarbon purge overhead stream comprising at least a portion of the propylene oxide from the organic phase stream, and discharge a solvent stripper bottoms comprising a lean hydrocarbon solvent.

11. A method, comprising:

(i) subjecting the crude propylene oxide stream to non-solvent distillation in a heavy ends distillation column to produce a crude propylene oxide stream comprising a solvent selected from the group consisting of acetone, methanol, aldehydes, aldehyde derivatives, water, and C₅+ a heavy purge bottoms of at least one impurity of a heavy hydrocarbon or combination thereof, and a heavy distillation column overhead stream comprising a majority of the propylene oxide entering the crude propylene oxide stream;

(ii) introducing the heavy distillation column overhead stream and a first extractive distillation solvent stream comprising a hydrocarbon solvent into a first extractive distillation column to produce a light wash overhead comprising at least one impurity selected from acetaldehyde, methyl formate, methanol, water, C3 hydrocarbons, C4 hydrocarbons, or a combination thereof, and a solvent-rich bottoms stream comprising a majority of the propylene oxide entering via the heavy distillation column overhead stream;

(iii) introducing the side extract from the first extractive distillation column into a decantation apparatus and allowing an aqueous phase purge comprising water and methanol, one or more glycols, or a combination thereof, and an organic phase stream comprising propylene oxide and the hydrocarbon solvent to form therein; and

(iv) the rich solvent bottoms stream from the first extractive distillation column is introduced into a first solvent stripper column to produce a first solvent stripper column overhead comprising a majority of the propylene oxide entering the first solvent stripper column via the rich solvent bottoms stream and a first solvent stripper column bottoms comprising the lean hydrocarbon solvent.

12. The method as set forth in claim 11 further comprising feeding a portion of the first solvent stripper bottoms comprising the lean hydrocarbon solvent to the first extractive distillation column and feeding another portion of the first solvent stripper bottoms comprising the lean hydrocarbon solvent to the decanter.

13. The process of claim 11, wherein the heavy purge bottoms comprises at least 10 wt% of the amount of methanol introduced with the crude propylene oxide stream, at least 40 wt% of the amount of water introduced with the crude propylene oxide stream, or both.

14. The method of claim 11, further comprising:

(v) subjecting the first solvent stripper overhead to extractive distillation by introducing the first solvent stripper overhead and a second extractive distillation solvent stream comprising the hydrocarbon solvent into a second extractive distillation column, thereby producing a purified propylene oxide product as an overhead stream and a second extractive distillation column bottoms comprising a hydrocarbon-rich solvent;

(vi) introducing the second extractive distillation column bottoms comprising hydrocarbon-rich solvent into a second solvent stripper column to produce a light hydrocarbon overhead purge stream and a second solvent stripper column bottoms comprising a lean hydrocarbon solvent; and

(vii) introducing at least a portion of the second solvent stripper bottoms into the second extractive distillation column, the first extractive distillation column, the decanter, or a combination thereof.

15. The process of claim 14, wherein the heavy distillation column is operated at a pressure in the range of from 0 to 60psig (0 to 414kPa gauge), at a temperature in the range of from 30 to 150 degrees celsius, or both; wherein the first extractive distillation column is operated at a pressure in the range of from 0 to 60psig (0 to 414kPa gauge), at a temperature in the range of from 30 to 200 degrees Celsius, or both; wherein the second extractive distillation column is operated at a pressure in the range of 0 to 60psig (0 to 414kPa gauge), at a temperature in the range of 30 to 200 degrees Celsius, or both; or a combination thereof.

16. A method, comprising:

(i) subjecting the crude propylene oxide stream to non-solvent distillation in a heavy ends distillation column to produce a crude propylene oxide stream comprising a solvent selected from the group consisting of acetone, methanol, aldehydes, aldehyde derivatives, water, and C₅+ a heavy purge bottoms of at least one impurity of a heavy hydrocarbon or combination thereof, and a heavy distillation column overhead stream comprising a majority of the propylene oxide entering the crude propylene oxide stream;

(ii) introducing the heavy distillation column overhead stream and a first extractive distillation solvent stream comprising a hydrocarbon solvent into a first extractive distillation column to produce a light wash overhead comprising at least one impurity selected from acetaldehyde, methyl formate, methanol, water, C3 hydrocarbons, C4 hydrocarbons, or a combination thereof, and a solvent-rich bottoms stream comprising a majority of the propylene oxide entering via the heavy distillation column overhead stream;

(iii) introducing at least a portion of the light purge overhead from the first extractive distillation column into a decantation apparatus and allowing an aqueous phase purge comprising water and methanol, one or more glycols, or a combination thereof, and an organic phase stream comprising propylene oxide and a hydrocarbon solvent to form therein; and

(iv) the rich solvent bottoms stream from the first extractive distillation column is introduced into a first solvent stripper column to produce a first solvent stripper column overhead comprising a majority of the propylene oxide entering the first solvent stripper column via the rich solvent bottoms stream and a first solvent stripper column bottoms comprising the lean hydrocarbon solvent.

17. The method as set forth in claim 16 further comprising feeding a portion of the first solvent stripper bottoms comprising the lean hydrocarbon solvent to the first extractive distillation column and feeding another portion of the first solvent stripper bottoms comprising the lean hydrocarbon solvent to the decanter.

18. The process of claim 16, wherein the heavy purge bottoms comprises at least 10 wt% of the amount of methanol introduced with the crude propylene oxide stream, at least 40 wt% of the amount of water introduced with the crude propylene oxide stream, or both.

19. The method of claim 16, further comprising:

(v) subjecting the first solvent stripper overhead to extractive distillation by introducing the first solvent stripper overhead and a second extractive distillation solvent stream comprising the hydrocarbon solvent into a second extractive distillation column, thereby producing a purified propylene oxide product as an overhead stream and a second extractive distillation column bottoms comprising a hydrocarbon-rich solvent;

(vi) introducing the second extractive distillation column bottoms comprising hydrocarbon-rich solvent into a second solvent stripper column to produce a light hydrocarbon overhead purge stream and a second solvent stripper column bottoms comprising a lean hydrocarbon solvent; and

(vii) introducing at least a portion of the second solvent stripper bottoms into the second extractive distillation column, the first extractive distillation column, the decanter, or a combination thereof.

20. The process of claim 19 wherein the heavy distillation column is operated at a pressure in the range of from 0 to 60psig (0 to 414kPa gauge), at a temperature in the range of from 30 to 150 degrees celsius, or both; wherein the first extractive distillation column is operated at a pressure in the range of from 0 to 60psig (0 to 414kPa gauge), at a temperature in the range of from 30 to 200 degrees Celsius, or both; wherein the second extractive distillation column is operated at a pressure in the range of 0 to 60psig (0 to 414kPa gauge), at a temperature in the range of 30 to 200 degrees Celsius, or both; or a combination thereof.

Technical Field

The present disclosure relates to a system and process for purifying and recovering propylene oxide formed by epoxidation of propylene with a hydroperoxide derived from the oxidation of isobutane, ethylbenzene, cyclohexane, alkylate or cumene. More particularly, the present disclosure relates to a system and method that provides a reduced amount of propylene oxide in the purge stream and/or facilitates separation of impurities, such as light impurities in the first extractive distillation column, thereby increasing propylene oxide yield, increasing purity, or both. Still more particularly, the present disclosure relates to systems and methods for purifying and recovering propylene oxide via a configuration that first removes selected heavy impurities ("heavy-first" configuration).

Background

Approximately 145 million pounds of Propylene Oxide (PO) are produced per year. Propylene oxide has many uses. 60-70% of the propylene oxide is converted into polyether polyols for the production of polyurethane plastics. About 20% of the propylene oxide is hydrolyzed to propylene glycol via a process accelerated by thermal reaction or by acid or base catalysis. Other major products are polypropylene glycol, propylene glycol ethers and propylene carbonate. To produce these end products, propylene oxide is required which is substantially free of impurities.

Processes for the production of alkylene oxides, including propylene oxide, involve hydrochlorination, direct oxidation and epoxidation of their corresponding alkenes by peroxides or hydroperoxides. The oxides used in the epoxidation process are derived from secondary or tertiary hydrocarbons by direct oxidation with molecular oxygen; thus, the oxide contains both oxygenate impurities and precursors. Additional oxygenate impurities are also produced in the olefin epoxidation step. Crude alkylene oxides, such as propylene oxide, particularly those produced by epoxidation with hydrocarbyloxides, contain oxygen-containing impurities in amounts that are difficult to separate from the alkylene oxide. Impurities may include water, acids, alcohols, aldehydes, alkanes, ketones, and esters. There is a continuing need for improved systems and methods for separating alkylene oxide from these impurity components of a crude alkylene oxide hydrocarbon stream.

Although the purity of crude propylene oxide (e.g., crude propylene oxide from propylene oxide and tert-butyl alcohol (PO/TBA) processes) can be as high as 98.5%, crude propylene oxide typically contains near-boiling impurities including, but not limited to, water, methanol, methyl formate, formaldehyde, acetaldehyde, acetone, propionaldehyde, isobutylene oxide, aldehyde derivatives, and C₅-C₇One or more of hydrocarbons. To meet commercial grade product propylene oxide specifications, impurities are removed from the crude propylene oxide. Due to the proximity of the boiling point, these impurities are difficult to separate from propylene oxide without the use of elaborate propylene oxide refining or purification schemes involving extractive distillation techniques.

Conventional propylene oxide purification involves producing a purge stream comprising propylene oxide (also known as 'tilted propylene oxide cuts'), which may be equal to 18 to 22 wt% of the propylene oxide in the crude propylene oxide entering the refining section. Such a purge stream comprising propylene oxide is typically used to produce Propylene Glycol (PG) to obtain added value in a propylene oxide purification/purification section at reduced equipment and energy costs. A reduction in PO loss in the purge stream can provide greater overall recovery of product PO, which may be desirable relative to making PG.

Recovery of a purified propylene oxide product containing low levels of impurities such as aldehydes and alcohols, particularly for propylene oxide produced by free radical oxidation processes, including, for example, the t-butyl hydroperoxide process, remains a challenge. Accordingly, there is a need for improved systems and methods for recovering propylene oxide in a high purity state from the effluent streams of various crude propylene oxide production processes without excessive loss of propylene oxide product.

Disclosure of Invention

Disclosed herein is a propylene oxide separation system comprising: a heavy distillation column configured to receive a crude propylene oxide stream and discharge a heavy purge bottoms comprising a component selected from the group consisting of acetone, methanol, aldehyde derivatives, water, oxidized isobutylene, and C₅+ a heavy hydrocarbon or a combination thereof and withdrawing a heavy distillation column overhead stream comprising a majority of the propylene oxide entering with the crude propylene oxide stream; and a first extractive distillation column configured to receive the heavy distillation column overhead stream and an extractive solvent stream comprising a hydrocarbon solvent and to discharge a stream comprising a hydrocarbon solvent selected from the group consisting of aldehydes, methyl formate, methanol, water, C₃Hydrocarbons, C₄A light purge overhead stream of at least one impurity of a hydrocarbon or combination thereof and withdrawing a solvent-rich bottoms stream comprising a majority of the propylene oxide entering via the heavy distillation column overhead stream.

Also disclosed herein is a method comprising: (i) subjecting the crude propylene oxide stream to non-solvent distillation in a heavy ends distillation column to produce a stream comprising a solvent selected from the group consisting of acetone, methanol, aldehydes, aldehyde derivatives, water, isobutylene oxide, C, and mixtures thereof₅+ a heavy purge bottoms of at least one impurity of a heavy hydrocarbon or combination thereof, and a heavy distillation column overhead stream comprising a majority of the propylene oxide entering the crude propylene oxide stream; (ii) introducing the heavy distillation column overhead stream and an extractive distillation solvent stream comprising a hydrocarbon solvent into a first extractive distillation column to produce a stream comprising a solvent selected from the group consisting of aldehydes, methyl formate, methanol, water, C₃Hydrocarbons, C₄A light purge overhead of at least one impurity of a hydrocarbon or combination thereof, and a rich solvent comprising a majority of propylene oxide entering via a heavy distillation column overhead streamA bottoms stream; (iii) transferring the side extract from the first extractive distillation column into a decantation apparatus and allowing an aqueous phase purge comprising water and methanol, one or more glycols, or a combination thereof, and an organic phase stream comprising propylene oxide and the hydrocarbon solvent to form therein; and (iv) introducing the rich solvent bottoms stream from the first extractive distillation column into a first solvent stripper column to produce a first solvent stripper column overhead comprising a majority of the propylene oxide entering the first solvent stripper column via the rich solvent bottoms stream and a first solvent stripper column bottoms comprising the lean hydrocarbon solvent.

Also disclosed herein is a method comprising: (i) subjecting the crude propylene oxide stream to non-solvent distillation in a heavy ends distillation column to produce a stream comprising a solvent selected from the group consisting of acetone, methanol, aldehydes, aldehyde derivatives, water, isobutylene oxide, C, and mixtures thereof₅+ a heavy purge bottoms of at least one impurity of a heavy hydrocarbon or combination thereof, and a heavy distillation column overhead stream comprising a majority of the propylene oxide entering the crude propylene oxide stream; (ii) introducing the heavy distillation column overhead stream and a first extractive distillation solvent stream comprising a hydrocarbon solvent into a first extractive distillation column to produce a light wash overhead comprising at least one impurity selected from aldehydes, methyl formate, methanol, water, C3 hydrocarbons, C4 hydrocarbons, or combinations thereof, and a solvent-rich bottoms stream comprising a majority of the propylene oxide entering via the heavy distillation column overhead stream; (iii) introducing at least a portion of the light purge overhead from the first extractive distillation column into a decantation apparatus and allowing an aqueous phase purge comprising water and methanol, one or more glycols, or a combination thereof, and an organic phase stream comprising propylene oxide and a hydrocarbon solvent to form therein; and (iv) introducing the rich solvent bottoms stream from the first extractive distillation column into a first solvent stripper column to produce a first solvent stripper column overhead comprising a majority of the propylene oxide entering the first solvent stripper column via the rich solvent bottoms stream and a first solvent stripper column bottoms comprising the lean hydrocarbon solvent.

While multiple embodiments are disclosed, other embodiments will become apparent to those skilled in the art from the following detailed description. As will be apparent, certain embodiments as disclosed herein can be modified in various respects, without departing from the spirit and scope of the claims presented herein. The following detailed description is, therefore, to be regarded as illustrative in nature and not as restrictive.

Drawings

The following figures illustrate embodiments of the subject matter disclosed herein. The claimed subject matter can be understood by reference to the following description taken in conjunction with the accompanying drawings, in which:

FIG. 1 is a schematic diagram of a propylene oxide separation system 100 according to an embodiment of the present disclosure;

FIG. 2 is a schematic diagram of a propylene oxide separation system 100A according to an embodiment of the present disclosure;

FIG. 3 is a schematic diagram of a propylene oxide separation system 100B according to an embodiment of the present disclosure;

FIG. 4 is a schematic diagram of a propylene oxide separation system 100C according to an embodiment of the present disclosure; and is

Fig. 5 is a schematic diagram of a propylene oxide separation system 100D according to an embodiment of the present disclosure.

Detailed Description

SUMMARY

The present disclosure may be understood more readily by reference to the following detailed description of various embodiments and the examples included therein. As used herein, "substantial portion" means greater than 50% by weight.

The present disclosure relates to systems and methods for removing impurities from a crude propylene oxide stream. Propylene Oxide (PO) is also known as propylene oxide (epyppane), propylene oxide (epypropane), 1,2-propylene oxide (1,2-propylene oxide), methyl ethylene oxide (methyl oxirane), 1,2-propylene oxide (1, 2-epyppane), propylene oxide (propene oxide), methyl ethylene oxide (methyl ethylene oxide), and methyl ethylene oxide (methyl ethylene oxide). PO can be produced in a PO/TBA process in which PO and tert-butanol (TBA, also known as 2-methyl-2-propanol and tert-butanol) are formed. In this PO/TBA process, Isobutane (IB), also known as 2-methylpropane, may first be reacted with oxygen to form tert-butyl hydroperoxide (TBHP), also known as tert-butyl hydroperoxide. Subsequently, propylene (propylene), also known as propylene (propene), can be reacted with TBHP in the presence of a catalyst to form PO and TBA. Since this process produces both PO and TBA, it is referred to herein as a PO/TBA process.

The crude propylene oxide purified via the systems and methods disclosed herein may be produced via any process known in the art. In embodiments, a crude PO stream purified via the systems and methods disclosed herein is formed in a PO/TBA process. The production of a crude PO stream, for example from a PO/TBA process, is known to those skilled in the art.

The PO/TBA process can also produce a variety of undesirable by-products or near boiling impurities that remain in the crude PO. Without wishing to be bound by theory, a non-selective reaction may occur to produce impurities. These impurities may include, but are not limited to, acetone, alcohols such as, but not limited to, methanol, formaldehyde, propionaldehyde, water, formic acid, methyl formate, acetaldehyde, hydrocarbons, aldehydes, oxidized isobutylene, and the like. For example, such non-selective reactions may include, but are not limited to, the production of acetone and methanol from TBHP; producing formaldehyde and water from methanol in the presence of oxygen; producing formic acid from formaldehyde in the presence of oxygen; producing methyl formate and water from formic acid and methanol; acetaldehyde and methanol, etc. are produced from PO and water. Other reactions and impurities are possible.

The concentration of these impurities ending up in the crude PO stream from the PO/TBA process can vary and their removal is effected to provide a purified PO product. Systems and methods for removing impurities from such a crude PO stream are disclosed herein. It has been unexpectedly found that removing heavies upstream of the extractive distillation increases the effectiveness of the downstream extractive distillation. Without wishing to be bound by theory, the removal of aldehydes and/or aldehyde derivatives (e.g., formaldehyde and/or methylene glycol and/or dimethoxymethane) as heavies in the upstream heavy distillation column bottoms as disclosed herein prevents or minimizes the downstream travel of aldehydes and/or aldehyde derivatives, where there is a potential for heavy decomposition at higher temperatures to form near-boiling impurities (e.g., methanol, water, formaldehyde) that can end up in the purified PO product. Such aldehyde derivatives (e.g., formaldehyde derivatives) can form rapidly, but are unstable, making their quantification difficult.

A propylene oxide separation system and process (also referred to herein as a PO separation system or process or a propylene oxide purification system or process) will now be described with reference to fig. 1, fig. 1 being a schematic diagram of a PO separation system 100 (also referred to as a "PO purification system") according to embodiments of the present disclosure. For clarity, the respective reboilers and overhead condensers (including any reflux systems) for each column (except for the condenser and associated reflux for the first extractive distillation column 120) are not shown in fig. 1. The systems and methods of the present disclosure provide for separating heavy from a crude PO stream by (non-solvent) distillation prior to (e.g., upstream of) further separation of impurities such as, but not limited to, extractive distillation to remove light purge streams, solvent stripping to provide a lean solvent for recycle, separation of PO product by extractive distillation, separation of a hydrocarbon purge stream from a lean solvent stream that may be recycled, and the like. For example, the PO separation system 100 comprises a heavy distillation column 110 configured to separate heavy from a crude PO stream introduced therein, thus providing a heavy purge bottoms and a heavy distillation column overhead stream comprising PO, the heavy distillation column 110 being located upstream of: an extractive distillation column (also referred to herein as the "first" extractive distillation column because the system may further comprise a second extractive distillation column downstream thereof) 120 configured for distillation of the heavy distillation column overhead stream, thus providing a light purge overhead and a first extractive distillation column bottoms comprising PO; a solvent stripper 130 (also referred to herein as a "first" solvent stripper, which may be referred to as a second solvent stripper downstream thereof) configured to separate a first extractive distillation bottoms comprising PO into a first solvent stripper bottoms comprising lean solvent and a first solvent stripper overhead comprising PO; a second extractive distillation column 140 configured to separate an overhead PO product from a second extractive distillation column bottoms comprising rich solvent from a first solvent stripper overhead comprising PO; and a second solvent stripper column 150 configured to separate a hydrocarbon wash overhead from the second extractive distillation column bottoms comprising the rich solvent to provide a second solvent stripper column bottoms comprising the lean solvent.

A crude PO stream is introduced into the heavy distillation column 110 via crude PO inlet line 101. As noted above, in embodiments, the crude PO stream can be the product of the catalytic epoxidation of propylene with an organic hydroperoxide, e.g., the crude PO stream can be a PO/TBA process effluent stream. The PO/TBA process effluent stream may not undergo any separation or distillation steps to remove impurities prior to being fed to the heavy ends distillation column 110. In embodiments, the crude PO stream may be the product of a PO/TBA process as described above. The crude PO stream comprises primarily PO and further comprises at least one impurity to be removed via the systems and methods disclosed herein. The crude PO stream can comprise propylene oxide in less than or equal to 96, 97, 98, or 99 wt.% propylene oxide purity.

Crude PO stream 101 can include, but is not limited to, any combination of the above-mentioned impurities with the desired product propylene oxide. As described above, the impurities may comprise one or more compounds selected from the group consisting of methyl formate, acetone, alcohols (including but not limited to methanol), oxygenated isobutylene, aldehydes and aldehyde derivatives (such as methylene glycol (CAS463-57-0) and/or methoxy methanol (CAS 4461-52-3)), water, light hydrocarbons (e.g., hydrocarbons containing three or more carbon atoms (C;)₃C), hydrocarbon containing three carbon atoms₃) Hydrocarbon (C) containing four carbon atoms₄) Or combinations thereof), heavy hydrocarbons (e.g., hydrocarbons containing five or more carbon atoms (C)₅C), hydrocarbons containing six or more carbon atoms (C)₆C), a hydrocarbon containing five carbon atoms (C)₅) Hydrocarbon (C) containing six carbon atoms₆) Or a combination thereof) and the like. In embodiments, the impurities comprise a compound selected from the group consisting of acetone, water, formaldehyde, methanol, methyl formate, acetaldehyde, propionaldehyde, isobutylene oxide, formaldehyde derivatives, C₅-C₇Hydrocarbons (which may comprise predominantly C)₆Propylene dimer) and the like. The aldehyde may include formaldehyde, acetaldehyde, and the like. Aldehyde derivatives, such as formaldehyde derivatives, include the heavier reaction products of the corresponding aldehydes. Such formaldehyde derivatives may include, but are not limited to, one or more hemiacetals, such as, but not limited to, methylene glycol (CAS463-57-0), hemiacetals (such as, but not limited to, methoxy methanol (CAS4461-52-3), propylene glycol hemiformal, and the like), acetals (such as, but not limited to, dimethoxymethane), paraformaldehyde, or a combination thereof.

Methyl formate may be present in the crude PO stream in an amount within a range having a lower limit and/or an upper limit, each expressed as a weight percentage of the total composition of the crude PO stream. The range may or may not include a lower limit and/or an upper limit. The lower and/or upper limit of methyl formate may be selected from 0, 0.01, 0.02, 0.03, 0.04, 0.05, 0.06, 0.07, 0.08, 0.09, 0.1, 0.11, 0.12, 0.13, 0.14, 0.15, 0.16, 0.17, 0.18, 0.19, 0.2, 0.21, 0.22, 0.23, 0.24, 0.25, 0.26, 0.27, 0.28, 0.29, 0.3, 0.31, 0.32, 0.33, 0.34, 0.35, 0.36, 0.37, 0.38, 0.39, 0.4, 0.41, 0.42, 0.43, 0.44, 0.45, 0.46, 0.47, 0.48, 0.49, 0.5, 0.51, 0.52, 0.51, 0.41, 0.42, 0.43, 0.44, 0.45, 0.46, 0.47, 0.48, 0.49, 0.5, 0.51, 0.54, 0.82, 0.73, 0.54, 0.73, 0.75, 0.54, 0.73, 0.75, 0.73, 0.75, 0.54, 0.73, 0.75, 0.73, 0.75, 0.73, 0.54, 0.73, 0.75, 0.73, 0.54, 0.73, 0.75. For example, methyl formate may be present in an amount greater than 0.02, 0.04, or 0.06 wt% of the total composition of the crude PO stream.

The one or more alcohols (e.g., without limitation, methanol) can be present in the crude PO stream in an amount within a range having a lower limit and/or an upper limit, each expressed as a weight percentage of the total composition of the crude PO stream. The range may or may not include a lower limit and/or an upper limit. One or more alcohol (e.g., methanol) lower and/or upper limits may be selected from 0, 0.001, 0.002, 0.003, 0.0031, 0.0032, 0.0033, 0.0034, 0.0035, 0.0036, 0.0037, 0.0038, 0.0039, 0.0139, 0.0239, 0.0339, 0.0439, 0.0539, 0.0639, 0.0739, 0.0839, 0.0939, 0.1039, 0.1049, 0.1059, 0.1069, 0.1079, 0.1089, 0.1099, 0.1109, 0.1119, 0.1129, 0.1139, 0.1149, 0.1159, 0.116, 0.1161, 0.1162, 0.1163, 0.1164, 0.1167, 0.1164, 0.117, 0.1164, 0.1173, 0.1164, 0.1175, 0.1164, 365, 0.1164, 365, 364, and 364 weight percent. For example, methanol may be present in an amount greater than 0.003, 0.03, 0.1172, or 0.3 wt% of the total composition of the crude PO stream.

Acetaldehyde may be present in the crude PO stream in an amount within a range having a lower limit and/or an upper limit, each expressed as a weight percentage of the total composition of the crude PO stream. The range may or may not include a lower limit and/or an upper limit. The lower and/or upper limit of acetaldehyde may be selected from 0, 0.01, 0.02, 0.03, 0.04, 0.05, 0.06, 0.07, 0.08, 0.09, 0.1, 0.11, 0.12, 0.13, 0.14, 0.15, 0.16, 0.17, 0.18, 0.19, 0.2, 0.21, 0.22, 0.23, 0.24, 0.25, 0.26, 0.27, 0.28, 0.29, 0.3, 0.31, 0.32, 0.33, 0.34, 0.35, 0.36, 0.37, 0.38, 0.39, 0.4, 0.41, 0.42, 0.43, 0.44, 0.45, 0.46, 0.47, 0.48, 0.49, 0.5, 0.51, 0.52, 0.53, 0.41, 0.42, 0.43, 0.44, 0.45, 0.46, 0.47, 0.48, 0.49, 0.5, 0.51, 0.52, 0.54, 0.73, 0.75, 0.73, 0.54, 0.73, 0.75, 0.73, 0.54, 0.75, 0.73, 0.75, 0.73, 0.75, 0.73, 0.75, 0.49, 0.75, 0.9, 0.73, 0.75. For example, acetaldehyde may be present in an amount greater than 0.03, 0.01, or 0.005 wt.% of the total composition of the crude PO stream.

Formaldehyde can be present in the crude PO stream in an amount within a range having a lower limit and/or an upper limit, each expressed as a weight percentage of the total composition of the crude PO stream. The range may or may not include a lower limit and/or an upper limit. The formaldehyde may be present in an amount selected from 0, 0.001, 0.002, 0.003, 0.004, 0.005, 0.006, 0.007, 0.008, 0.009, 0.01, 0.02, 0.03, 0.04, 0.05, 0.06, 0.07, 0.08, 0.09, 0.1, 0.11, 0.12, 0.13, 0.14, 0.15, 0.16, 0.17, 0.18, 0.19, 0.2, 0.21, 0.22, 0.23, 0.24, 0.25, 0.26, 0.27, 0.28, 0.29, 0.3, 0.31, 0.32, 0.33, 0.34, 0.35, 0.36, 0.37, 0.38, 0.39, 0.4, 0.41, 0.42, 0.43, 0.44, 0.32, 0.33, 0.34, 0.35, 0.36, 0.37, 0.38, 0.39, 0.4, 0.41, 0.42, 0.43, 0.44, 0.82, 0.54, 0.27, 0.54, 0.27, 0.54, 0.27, 0.54, 0.27, 0.54, 0.67, 0.54, 0.75, 0.54, 0.27. For example, formaldehyde may be present in an amount greater than 0.003, 0.005, 0.01, or 0.02 wt% of the total composition of the crude PO stream.

Water may be present in the crude PO stream in an amount within a range having a lower limit and/or an upper limit, each expressed as a weight percentage of the total composition of the crude PO stream. The range may or may not include a lower limit and/or an upper limit. The lower and/or upper limit of water may be selected from 0, 0.01, 0.02, 0.03, 0.04, 0.05, 0.06, 0.07, 0.08, 0.09, 0.1, 0.11, 0.12, 0.13, 0.14, 0.15, 0.16, 0.17, 0.18, 0.19, 0.2, 0.21, 0.22, 0.23, 0.24, 0.25, 0.26, 0.27, 0.28, 0.29, 0.3, 0.31, 0.32, 0.33, 0.34, 0.35, 0.36, 0.37, 0.38, 0.39, 0.4, 0.41, 0.42, 0.43, 0.44, 0.45, 0.46, 0.47, 0.48, 0.49, 0.5, 0.51, 0.52, 0.53, 0.41, 0.42, 0.43, 0.44, 0.45, 0.46, 0.47, 0.48, 0.49, 0.5, 0.52, 0.54, 0.73, 0.82, 0.73, 0.54, 0.73, 0.75, 0.54, 0.75, 0.73, 0.75, 0.73, 0.75, 0.49, 0.75, 0.73, 0.75, 0.9, 0.73, 0.54, 0.75, 0.73, 0.75, 0.95, 0.75, 0.73, 0.75, 0.9, 0.73, 0.75. For example, water may be present in an amount greater than 0.16, 0.2, 0.3, or 0.8 wt% of the total composition of the crude PO stream.

For example, the crude PO stream can comprise (each expressed as an average weight percentage of the total composition of the crude PO stream): 0.05 to 1.5, 0.02 to 1.0 or 0.01 to 0.07 wt.% of methyl formate (MeF), 0.05 to 1.5, 0.1 to 1.0 or 0.2 to 0.8 wt.% of methanol (MeOH), 0.001 to 0.03, 0.003 to 0.02 or 0.004 to 0.04 wt.% of aldehydes and/or aldehyde derivatives, 0.001 to 0.05, 0.003 to 0.03 or 0.006 to 0.04 wt.% of acetaldehyde (AA), 0.001 to 0.04, 0.002 to 0.03 or 0.003 to 0.02 wt.% of Formaldehyde (FA), 0.05 to 1.5, 0.1 to 1.0 or 0.2 to 0.8 wt.% of water, 0.001 to 0.5, 0.002 to 0.4 or 0.01 to 0.3 wt.% of hydrocarbons, 0.01 to 0.03 or 0.08 to 0.06 wt.% of light hydrocarbons (c.06 wt.%)₃+ hydrocarbons, C₃A hydrocarbon,C₄Hydrocarbons or combinations thereof), 0.01 to 0.2, 0.02 to 0.15, or 0.03 to 0.1 wt.% of heavy hydrocarbons (C)₅+、C₆+、C₅、C₆Or a combination thereof) or a combination thereof.

Distillation of the crude PO stream within the heavy distillation column 110 produces a heavy purge bottoms that is removed from the heavy distillation column 110 via the heavy distillation column bottoms line 102 and a heavy distillation column overhead that is removed from the heavy distillation column 110 via the heavy distillation column overhead line 103. The heavy distillation column overhead stream comprises a majority of the PO introduced into the heavy distillation column 110 via crude PO inlet line 101.

The heavy ends distillation column 110 may be a non-solvent distillation column and may be made of any suitable material, including but not limited to carbon steel, stainless steel, Fiberglass Reinforced Polymer (FRP), nickel alloys, and the like. The heavy distillation column 110 may include any suitable number of theoretical plates or trays, for example about 30, 60, or 100 theoretical plates. In embodiments, the crude PO stream may be introduced to the heavy distillation column 110 at least 15%, 20%, or 25% upward from the bottom. In embodiments, the crude PO stream can be introduced into the heavy distillation column 110 at or between any of trays 5 to 20 (including 5 and 20) counted from the bottom thereof. Packing materials may be used in the heavy ends distillation column to enhance vapor-liquid contact. The filler material may be made of any suitable material, including but not limited to glass, metal, plastic, or ceramic. The fillers may be structured or random. Trays such as sieve trays, bubble cap trays or valve trays may also be used.

In embodiments, the heavy distillation column 110 may be operated at a temperature in the range of 30 to 150 degrees celsius (° c), 35 ℃ to 125 ℃, or 40 ℃ to 100 ℃. In embodiments, heavy distillation column 110 can be operated at a pressure of from 0psig to 60psig (0kPa gauge to 414kPa gauge), from 0psig to 45psig (0kPa gauge to 311kPa gauge), or from 0psig to 25psig (0kPa gauge to 138kPa gauge).

Without wishing to be bound by theory, the PO separation system and method of the present disclosure including the prior heavies removal via heavies distillation column 110 may provide enhanced removal of at least one aldehyde and/or methanol due to the removal via heavies removalRemoval of hemiacetals and/or acetals. Aldehyde (having the formula R₁CHO), e.g. formaldehyde, may be reacted with an alcohol (of formula R)₂OH), such as but not limited to methanol, to form a hemiacetal (having the formula R)₁HC(OH)OR₂Wherein R is₁And R₂May be, for example, hydrogen or C₁To C₁₀An alkyl group. Examples of hemiacetals are methylene glycol (CAS463-57-0) and methoxy methanol (CAS4461-52-3) or other compounds produced via an aldehyde/alcohol combination. When the hydroxyl group of the hemiacetal is protonated and lost as water, acetal formation may occur. In solvent systems, formaldehyde and methanol are both light in nature, but the hemiacetals and acetals formed therefrom may be heavy. Subsequently, if not removed via the heavy purge bottoms from the heavy distillation column 110 or the light purge from the first extractive distillation column 120, these additional products can travel downstream (along with PO in the rich solvent bottoms stream in the first extractive distillation bottoms line 122 described below) where the temperature can be raised and the reaction reversed. When the reaction is reversed, such aldehydes and/or alcohols may become undesirably associated with the PO product.

Since the higher content of methanol and/or water in the crude PO stream can provide enhanced removal of aldehydes and/or aldehyde derivatives (such as, but not limited to, formaldehyde derivatives) via the heavy distillation column 110, as well as a purer product PO stream (e.g., an overhead PO product stream extracted from the second extractive distillation column 140 via the second extractive distillation column overhead line 143, discussed further below), the line 104A can be configured for introducing methanol into the crude PO stream, the line 104B can be configured for introducing water into the crude PO stream, or both. In embodiments, water and methanol are present in the feed to the heavy distillation column 110 at the levels provided above. Water, methanol, or both can be added to the crude PO stream from the PO/TBA process to provide the desired levels of methanol and/or water within the heavy ends distillation column 110. In embodiments, the amount of methanol and/or water in the crude PO stream introduced into the heavy distillation column 110 can be adjusted (methanol addition via line 104A and/or water addition via line 104B) to a desired level based on the total aldehyde concentration in the heavy distillation column overhead removed via heavy distillation column overhead line 103. In embodiments, the desired level of methanol in the feed to the heavy distillation column 110 (i.e., the amount of methanol in the crude PO stream or the amount of methanol in the crude PO stream combined with the amount of methanol introduced via inlet line 104A) comprises 0.05 to 0.7, 0.1 to 0.5, or 0.2 to 0.4 wt% methanol. In embodiments, the desired level of water in the feed to the heavy distillation column 110 (i.e., the amount of water in the crude PO stream or the amount of water in the crude PO stream combined with the amount of water introduced via inlet line 104B) comprises from 0.1 to 1.0, from 0.2 to 0.8, or from 0.3 to 0.6 wt.% water. Although methanol is specifically noted herein, other alcohols may be used in alcohol inlet line 104A and/or may be present in the crude PO stream introduced via crude PO inlet line 101, or methanol is mentioned elsewhere herein.

The heavy purge bottoms removed via heavy purge bottoms line 102 can comprise one or more compounds selected from the group consisting of acetone, methanol, aldehydes and aldehyde derivatives, water, heavy hydrocarbons (i.e., C)₅+、C₆+、C₅、C₆Or a combination thereof), acrolein, Propionaldehyde (PA), isobutylene oxide (IBO), formic acid, or a combination thereof. In embodiments, the heavy purge bottoms comprises at least one selected from the group consisting of acetone, methanol, aldehydes and aldehyde derivatives, water, heavy hydrocarbons, or combinations thereof. The aldehyde and aldehyde derivative may comprise formaldehyde and/or a formaldehyde derivative. In embodiments, the heavy purge bottoms removed from the heavy distillation column 110 via the heavy purge bottoms line 102 comprises at least 10, 15, 20, 25, or 30 wt% methanol introduced with the crude PO stream via the crude PO inlet line 101. In embodiments, the heavy purge bottoms removed from the heavy distillation column 110 via the heavy purge bottoms line 102 comprises at least 40, 45, 50, 55, or 60 wt% of the water introduced with the crude PO stream via the crude PO inlet line 101.

The heavy distillation column overhead stream removed via heavy distillation column overhead line 103 comprises a majority of the PO introduced into heavy distillation column 110 with the crude PO stream, and may further comprise (each expressed as an average weight percentage of the total composition of the heavy distillation column overhead stream): 0.02 to 0.08, 0.03 to 0.07 or 0.04 to 0.06% by weight of methyl formate (MeF), 0.1 to 0.5, 0From 2 to 0.4 or from 0.25 to 0.35% by weight of methanol (MeOH), from 0.005 to 0.05, from 0.01 to 0.04 or from 0.015 to 0.03% by weight of aldehydes and/or aldehyde derivatives, from 0.002 to 0.04, from 0.003 to 0.03 or from 0.004 to 0.02% by weight of acetaldehyde (AA), from 0.0 to 0.01, from 0.0 to 0.005 or from 0.0 to 0.0001% by weight of Formaldehyde (FA), from 0.05 to 0.5, from 0.03 to 0.4 or from 0.01 to 0.3% by weight of water, from 0.01 to 0.2, from 0.03 to 0.5 or from 0.05 to 0.8% by weight of hydrocarbons, from 0.005 to 0.08, from 0.015 to 0.1 or from 0.02 to 0.3% by weight of light hydrocarbons (C)₃+ hydrocarbons, C₃Hydrocarbons, C₄Hydrocarbons or combinations thereof), 0.001 to 0.02, 0.002 to 0.01, or 0.003 to 0.008 wt.% of heavy hydrocarbons (C)₅+ hydrocarbons, C₆+ hydrocarbons, C₅Hydrocarbons, C₆Hydrocarbons or combinations thereof) or combinations thereof.

The heavy distillation column overhead stream is introduced into an extractive distillation column 120 (which, as noted above, may be referred to as a "first" extractive distillation column in a system further comprising a second extractive distillation column downstream thereof) via heavy distillation column overhead line 103, which is configured for removing a first extractive distillation column overhead comprising a majority of the impurities (e.g., methanol) introduced therein and a first extractive distillation column bottoms comprising a majority of the PO introduced into first extractive distillation column 120.

The first extractive distillation column 120 is operable to separate, via distillation, a first extractive distillation column overhead or "light purge" comprising at least one impurity from a stream comprising a major portion of the PO introduced into the first extractive distillation column via the heavy distillation column overhead line 103 with the extractive solvent introduced thereto via the first extractive distillation column extractive solvent inlet line 129. In embodiments, the lean extraction solvent introduced via first extractive distillation column extractive solvent inlet line 129, and the lean extraction solvent (described below), the rich solvent, and the lean solvent referred to below introduced via second extractive distillation column extractive solvent inlet line 151 into second extractive distillation column 140 comprise a mixture comprising one or more C' s₆-C₂₀Alkanes or one or more C₆-C₁₀A paraffinic hydrocarbon solvent. For example, in embodiments, the hydrocarbon solvent comprises primarily octane.

The first extractive distillation column 120 may be made of any suitable material, including but not limited to carbon steel, stainless steel, Fiberglass Reinforced Polymer (FRP), nickel alloys, and the like. The first extractive distillation column 120 can include any suitable number of trays or theoretical plates, for example about 25, 30, 35, 40, or 45 theoretical plates. In particular embodiments, the heavy distillation column overhead stream from the heavy distillation column 110 may be introduced into the first extractive distillation column 120 via the heavy distillation column overhead line 103 at a location from 45% to 85%, about 50% to 80%, 55% to 75%, or at least 45%, 50%, or 55% proceeding upward from the bottom of the first extractive distillation column 120. Packing materials may be used in the first extractive distillation column to enhance gas-liquid contact. The filler material may be made of any suitable material known to those skilled in the art, including but not limited to glass, metal, plastic, or ceramic. The fillers may be structured or random. Trays such as sieve trays, bubble cap trays or valve trays may also be used.

In embodiments, the first extractive distillation column 120 can be operated at a temperature in a range from 50 to 150 degrees celsius (° c), 40 ℃ to 175 ℃, or 30 ℃ to 200 ℃. In embodiments, the first extractive distillation column 120 can be operated at a pressure of from 0psig to 60psig (0kPa gauge to 414kPa gauge), from 10psig to 50psig (69kPa gauge to 350kPa gauge), or from 15psig to 45psig (104kPa gauge to 311kPa gauge). In embodiments, the first extractive distillation column 120 can be an extractive distillation column as described in U.S. patent No. 9,593,090, the disclosure of which is incorporated by reference herein in its entirety for purposes not contrary to the present disclosure. However, as described further below, the use of a heavy distillation upstream of the first extractive distillation column 120 may enable the first extractive distillation column 120 to operate at lower operating conditions than those described in U.S. patent No. 9,593,090.

The first extractive distillation column overhead, or "light purge," comprises at least one impurity and is removed from the first extractive distillation column 120 via first extractive distillation column overhead line 123. A cooler 124 may be used to reduce the temperature of the first extractive distillation column overhead introduced into it from the first extractive distillation column overhead line 123. In embodiments, cooler 124 is operated to reduce the temperature of the first extractive distillation column overhead from a temperature in the range of 50 ℃ to 65 ℃, 70 ℃ to 90 ℃, or 35 ℃ to 50 ℃ to a temperature in the range of 40 ℃ to 50 ℃, 45 ℃ to 70 ℃, or 25 ℃ to 35 ℃.

A separation (knock out) (K/O)121 may be used to separate the gas comprising the uncondensed components from the liquid comprising the condensed components. The uncondensed components or 'vapor purge' outlet line 125A is operable to remove gas containing uncondensed components from the K/O121 and the condensed components outlet line 126 is operable to remove liquid containing condensed components from the K/O121. Uncondensed components in the overhead stream in the first extractive distillation column overhead line 123 to the K/O121 can be purged from the PO separation system 100 via vapor purge line 125A. These uncondensed components in vapor purge line 125A can be sent to another process, vented as waste, and the like. If desired, the uncondensed components in vapor purge line 125A may be subjected to further local processing, such as in an additional condenser operating at a lower temperature than that of K/O121, and so forth. In embodiments, the uncondensed components in vapor purge line 125A can include acetaldehyde, methyl formate, and/or other undesirable impurities.

A portion of the condensate from K/O121 may be returned to first edc 120 as reflux via first edc overhead reflux line 126A, and a portion of the condensate from K/O121 may be removed from the system as a liquid light purge via liquid light purge line 126B.

The light purge removed via first edc overhead line 123, vapor light purge 125A and/or liquid light purge line 126B may comprise one or more compounds selected from aldehydes (e.g., acetaldehyde (AA), formaldehyde, etc.), Methyl Formate (MF), methanol (MeOH), water, C, and the like)₃(i.e., hydrocarbons containing three carbons), C₄(i.e., a hydrocarbon containing four carbons) or a combination thereof.

In embodiments, the first extractive distillation column 120 is further configured to discharge a side extract. For example, in the embodiment of fig. 1, the first extractive distillation column 120 is configured with a side extract line 127 whereby a liquid side extract can be removed from the first extractive distillation column 120. The liquid side extract in line 127 from the first extractive distillation column 120 can comprise PO, water, methanol, acetaldehyde, glycols, and/or other impurities, and can be introduced to the decanter 115. The decanter 115 can facilitate the removal of water, glycols, and other water soluble impurities from the first extractive distillation column 120 via an aqueous phase purge. For example, the liquid side extract removed via the liquid side extract line 127 can be combined with water in the water inlet line 128 and with a solvent (e.g., a lean solvent), such as via the decanter lean solvent line 118 (which can be fluidly connected to the first solvent stripper 130, the second solvent stripper 150, or both, as described in more detail below), and introduced into the decanter 115 via the decanter feed line 114.

Decanter 115 is configured to separate the aqueous phase from the organic phase. Although referred to as a 'decanter' in embodiments, decanter 115 comprises one or more of a mixer, a coalescer, and a decanter. The mixer may comprise an orifice mixer, a static mixer, or the like. The decanter 115 may comprise a decanter and/or a water washing system as described in U.S. patent No. 9,593,090, or any other suitable water washing and decanting system, and may be referred to as a 'water wash decanter'. The aqueous phase purge having a high concentration of impurities may be purged from the decanter 115 via an aqueous phase purge outlet line 116. The aqueous wash may comprise, for example, water, methanol, one or more glycols, methyl formate, aldehydes (e.g., acetaldehyde, formaldehyde, etc.), aldehyde derivatives, other aqueous phase impurities, or combinations thereof. The aqueous phase purge may comprise a majority weight percent of methanol and water fed to the decanter 115 in decanter feed line 114. As noted above, and without wishing to be bound by theory, the source of the glycol impurity in the PO separation system 100 can be various solvents therein that degrade over time in the presence of water and propylene oxide, such as the formation of glycols. By removing impurities (e.g., water and propylene glycol), the hydrocarbon solvent performance in the PO separation system 100 can be maintained. In embodiments, the aqueous phase purge comprises 10 to 50, 15 to 45, or 20 to 40 weight percent methanol. In embodiments, the aqueous wash comprises 0.1 to 5.0, 0.2 to 2.5, or 0.3 to 1.0 wt% of one or more glycols.

The organic phase may be removed from decanter 115 via organic phase outlet line 117. The organic phase may comprise, for example, an extraction solvent, propylene oxide, or a combination thereof. In embodiments, the organic phase comprises from 50 to 95, from 60 to 90, or from 70 to 90 weight percent of the extraction solvent. In embodiments, the organic phase comprises from 5 to 30, from 7 to 25, or from 10 to 20 weight percent propylene oxide. The organic phase in organic phase outlet line 117 and/or first extractive distillation column solvent inlet line 129 can include an amount of the aqueous phase within a range having a lower limit and/or an upper limit, each expressed as a weight percentage. The range may or may not include a lower limit and/or an upper limit. The lower and/or upper limit of the amount of aqueous phase in the organic phase may be selected from 0, 0.01, 0.02, 0.03, 0.04, 0.05, 0.1, 0.2, 0.3, 0.4, 0.5, 0.7, 1,2, 3, 4, 5, 6, 7, 8, 9 and 10 wt%. For example, less than 0.1% of the aqueous phase may be present in the washed organic phase effluent or less than 10% of the aqueous phase may be present in the washed organic phase effluent.

The water wash in decanter 115 can be performed by combining the liquid side extract (comprising propylene oxide and impurities) in side extract line 127 with water and a solvent (e.g., a hydrocarbon solvent). Water supplied via inlet pipe 128 may be used to remove impurities from the propylene oxide. The water introduced via inlet line 128 may comprise tap water, treated water, demineralized water, deionized water, recycled process water, or combinations thereof. The solvent supplied via the decanter lean solvent line 118 can be used to reduce propylene oxide losses into the aqueous phase. Thorough mixing may facilitate impurity removal. Sufficient coalescence and sufficient residence time in decanter 115 can also help reduce entrainment of the aqueous phase in the organic phase effluent. It should be noted that other configurations of the first edc 120 and decanter 115 are contemplated to form and discharge an aqueous phase purge. Other configurations are taught, for example, in U.S. patent No. 9,593,090.

The first extractive distillation column extractive solvent inlet line 129 is configured to introduce extractive solvent into the first extractive distillation column 120 at a point in the range of 65% to 95%, 65% to 90%, 70% to 90%, or at least 60%, 65%, or 70% upward from the bottom of the first extractive distillation column 120. In embodiments, the solvent recovered from the decanter 115 in the organic phase may be recycled to the first extractive distillation column 120 such that the PO and/or hydrocarbon solvent therein may be recovered or reused.

Removal of the light and aqueous purge via the first extractive distillation column 120 and the decanter 115 effectively removes various light impurities such as, but not limited to, methyl formate, formaldehyde, acetaldehyde, aldehyde derivatives, water, and methanol. This can help to keep hemiacetal and/or acetal formation low in the first extractive distillation column 120. As described above, hemiacetals and acetals may undesirably enter the solvent-rich bottoms in the first extractive distillation bottoms line 122, then decompose into aldehydes and alcohols in the downstream column to contaminate the propylene oxide product, and removal of the hemiacetals, acetals, and/or precursors thereof via the heavies distillation column 110, first extractive distillation column 120, and/or decanter 115 may minimize the presence of impurities in the purified PO product (e.g., an overhead PO product stream removed from the second extractive distillation column 140 via the second extractive distillation overhead line 143).

The impurities removed via the first extractive distillation column 120 may include methyl formate, formaldehyde, acetaldehyde, methanol, water, or a combination thereof. Most of the impurities in the light purge overhead removed from the first extractive distillation column 120 via the first extractive distillation column overhead line 123 can be removed by a combination of the vapor purge gas in the uncondensed components outlet line 125A, the liquid light purge in the liquid light purge line 126B, and the aqueous purge in the aqueous phase purge outlet line 116 from the decanter 115.

The solvent stripper 130 (which may be referred to herein as a 'first' solvent stripper when a second solvent stripper 150 is used downstream thereof) may be used to separate the hydrocarbon solvent from a rich solvent bottoms stream that is removed from the first extractive distillation column 120 and introduced into the first solvent stripper 130 via the first extractive distillation bottoms line 122.

The first solvent stripper 130 may comprise a tray stripper or a stripper containing packing. The first solvent stripper 130 may be made of any suitable material including, but not limited to, stainless steel, carbon steel, Fiberglass Reinforced Polymer (FRP), nickel alloys, and the like. The first solvent stripper 130 can include any suitable number of trays or theoretical plates, such as about 0, 5, 10, or 15 theoretical plates. The rich solvent bottoms in the first extractive distillation bottoms line 122 can be introduced into the first solvent stripper 130 at the top of the tray section or the packing section. Packing materials may be used in the first solvent stripper 130 to enhance gas-liquid contacting. The filler material may be made of any suitable material, including but not limited to glass, metal, plastic, and ceramic. If a filler is used, it may be structured or random, etc. If trays are used, the trays may be sieve trays, bubble cap trays, valve trays, or the like.

In embodiments, the first solvent stripper 130 may be operated at a temperature in a range of 80 to 200 degrees celsius (° c), 90 ℃ to 180 ℃, or 100 ℃ to 175 ℃. In embodiments, the first solvent stripper 130 can be operated at a pressure of 0psig to 40psig (0kPa gauge to 276kPa gauge), 10psig to 40psig (69kPa gauge to 276kPa gauge), 15psig to 30psig (104kPa gauge to 210kPa gauge), or 17psig to 35psig (118kPa gauge to 244kPa gauge).

First solvent stripper overhead line 133 is configured to remove a first solvent stripper overhead comprising a majority of the propylene oxide entering with the rich solvent bottoms stream, and first solvent stripper bottoms line 132 is configured to remove a first solvent stripper bottoms comprising the lean solvent. The first solvent stripper column 130 can be fluidly connected to the first extractive distillation column 120 (e.g., via a first solvent stripper column bottom line 132 and a first extractive distillation column extractive solvent inlet line 129) such that at least a portion of the lean solvent separated from the rich solvent bottoms stream in the first solvent stripper column 130 can be introduced into the first extractive distillation column 120 as the extractive solvent. Alternatively or additionally, the first solvent stripper 130 may be fluidly connected to the decanter 115 (e.g., via a combination of the first solvent stripper bottoms line 132, the first extractive distillation column extraction solvent inlet line 129, and/or the decanter lean solvent inlet line 118) such that at least a portion of the lean solvent separated from the rich solvent bottoms stream in the first solvent stripper 130 may be introduced into the decanter 115.

The second extractive distillation column 140 can be configured to separate the first solvent stripper overhead into a second extractive distillation column overhead comprising a PO product stream comprising a majority of the PO introduced into the second extractive distillation column 140 via the first solvent stripper overhead and a second extractive distillation column bottoms comprising the rich solvent. The second extractive distillation column 140 is operable to separate a second extractive distillation column or 'PO product' overhead comprising a majority of the PO introduced into the second extractive distillation column 140 via the first solvent stripper overhead line 133 from a second extractive distillation column bottoms comprising a rich solvent via distillation with extractive solvent. A second extractive distillation column overhead comprising PO product is removed from the second extractive distillation column 140 via second extractive distillation column overhead line 143. The second extractive distillation bottoms line 142 can be configured to remove a second extractive distillation column bottoms comprising rich solvent from the second extractive distillation column 140. The extractive solvent may be introduced into the second extractive distillation column 140 via a second extractive distillation column extractive solvent inlet line 151, which second extractive distillation column extractive solvent inlet line 151 may be fluidly connected to a second solvent stripper column 150, as further described below. The extractive solvent may be introduced into the second extractive distillation column 140 at a point from the bottom up to 50% to 90%, 60% to 90%, or 50% to 85%.

The second extractive distillation column 140 can be made of any suitable material including, but not limited to, carbon steel, stainless steel, Fiberglass Reinforced Polymer (FRP), nickel alloys, and the like. The second extractive distillation column 140 can include any suitable number of trays or theoretical plates, such as about 50, 40, or 30 theoretical plates. In embodiments, the first solvent stripper overhead in the first solvent stripper overhead line 133 from the first solvent stripper 130 can be introduced into the second extractive distillation column 140 at a point that is at least 15%, 20%, or 25% from its bottom. Packing materials may be used in the second extractive distillation column 140 to enhance gas-liquid contact. The filler material may be made of any suitable material, including but not limited to glass, metal, plastic, or ceramic. The fillers may be structured or random. Trays such as sieve trays, bubble cap trays or valve trays may also be used.

In embodiments, the second extractive distillation column 140 can be operated at a temperature in a range of 30 to 250 degrees celsius (° c), 40 ℃ to 200 ℃, or 45 ℃ to 175 ℃. In embodiments, the second extractive distillation column 140 can be operated at a pressure of from 0psig to 60psig (0kPa gauge to 414kPa gauge), from 5psig to 50psig (35kPa gauge to 350kPa gauge), or from 10psig to 40psig (69kPa gauge to 276kPa gauge).

The PO product removed from second edc 140 via second edc overhead line 143 may comprise less than 0.010, 0.005, 0.004, 0.003, 0.002 or 0.001 wt% (less than 100, 50, 40, 30, 20 or 10ppm) methanol, less than 0.010, 0.005, 0.004, 0.003, 0.002, 0.001 or 0.0005 wt% (less than 100, 50, 40, 30, 20, 10 or 5ppm) methyl formate, less than 0.025, 0.010 or 0.005 wt% (less than 250, 100 or 50ppm) water, less than 0.005, 0.002 or 0.001 wt% (less than 50, 20 or 10ppm) acetaldehyde, less than 0.001, 0.0005, or 0.0001 wt% (less than 10, 5 or 1ppm) formaldehyde and/or aldehyde derivatives, or combinations thereof. The propylene oxide purity of the overhead PO product in second extractive distillation column overhead line 143 (i.e., the distillate of second extractive distillation column 140) can be greater than or equal to 99.0, 99.9, 99.98, or 99.99 wt.% propylene oxide. Such purified PO (e.g., PO purity having greater than or equal to 99.0, 99.9, 99.98, or 99.99 wt% propylene oxide) may be referred to herein as 'pure' PO. The PO separation system 100 and method of the present disclosure including pre-heavies removal may result in relatively high yields of greater than or equal to 90, 95, or 98 wt% PO recovery from the crude PO stream in the crude PO inlet line 101 being recovered as the PO product in the condensed second extractive distillation column overhead in the second extractive distillation column overhead line 143 that is sent out as a distillate product.

The second extractive distillation bottoms line 142 can be configured to introduce a second extractive distillation bottoms comprising rich solvent into the second solvent stripper column 150. The second solvent stripper 150 may include a distillation column. The second solvent stripper 150 may be made of any suitable material including, but not limited to, stainless steel, carbon steel, Fiberglass Reinforced Polymer (FRP), nickel alloys, and the like. The second solvent stripper 150 can include any suitable number of theoretical plates, for example, about 30, 25, 20, 15, or 10 theoretical plates. The second extractive distillation column bottoms in the second extractive distillation column bottoms line 142 comprising rich solvent can be introduced into the second solvent stripper column 150 at a point from its bottom up 60% to 95%, 65% to 90%, or 70% to 85%. Packing materials may be used in the second solvent stripper 150 to enhance gas-liquid contacting. The filler material may be made of any suitable material, including but not limited to glass, metal, plastic, and ceramic. If a filler is used, it may be structured or random, etc. If trays are used, the trays may be sieve trays, bubble cap trays, valve trays, or the like.

In embodiments, the second solvent stripper 150 may be operated at a temperature in a range of 40 to 200 degrees celsius (° c), 45 ℃ to 190 ℃, or 45 ℃ to 180 ℃. In embodiments, second solvent stripper 150 can be operated at a pressure in the range of from 5psig to 45psig (35kPa gauge to 311kPa gauge, or from 5psig to 30psig (35kPa gauge to 207kPa gauge, or from 15psig to 45psig (104kPa gauge to 311kPa gauge).

The second solvent stripper overhead line 153 may be configured for removal of hydrocarbon-containing impurities, such as, but not limited to, C₅、C₆And/or C₇A light hydrocarbon purge stream of hydrocarbons. In embodiments, the light hydrocarbon purge in the second solvent stripper overhead line 153 comprises primarily C₆Mainly comprises C₇Or a combination thereof. For example, such hydrocarbon impurities include, but are not limited to, 2-methylpentane, propylene glycol methyl ether and various C' s₅+ hydrocarbons. (although referred to as a light hydrocarbon purge, relative to the hydrocarbons (primarily C) removed via the liquid light purge line 126B₃And C₄) The hydrocarbons in the light hydrocarbon purge may be considered 'heavy' hydrocarbons. ) Second solvent stripper bottoms line 152 can be configured to remove solvent containing lean solvent (e.g., primarily C)₈-C₂₀A hydrocarbon (e.g., primarily octane)) to the second solvent stripper bottoms. In embodiments, at least a portion of the lean solvent in the second solvent stripper bottoms may be introduced to the second extractive distillation column via second extractive distillation column extractive solvent inlet line 151140, as discussed above. In embodiments, at least a portion of the lean solvent in the second solvent stripper bottoms may be introduced into the first extractive distillation column 120 via the second solvent stripper bottoms line 152 via the first extractive distillation column extractive solvent inlet line 129. In embodiments, at least a portion of the lean solvent in the second solvent stripper bottoms may be introduced into the decanter 115 via the second solvent stripper bottoms line 152 via the first extractive distillation column extraction solvent inlet line 129, the water decanter lean solvent line 118, and/or the decanter feed line 114.

Fig. 2 is a schematic diagram of a propylene oxide separation system 100A according to another embodiment of the present disclosure. In the embodiment of fig. 2, the side extract line 127 of the embodiment shown in fig. 1 is replaced with line 126C. Line 126C can be configured such that a portion of the condensate from K/O121 can be combined with decanter lean solvent line 118 in combined line 118A. Additionally, in the embodiment of fig. 2, the organic phase in organic phase outlet line 117 from decanter 115 can be directed to first extractive distillation column 120. In some implementations, the organic phase in the organic phase outlet line 117 can be combined with the first extractive distillation column solvent in the first extractive distillation column solvent inlet line 129 prior to entering the first extractive distillation column 120.

Fig. 3 is a schematic diagram of a propylene oxide separation system 100B according to another embodiment of the present disclosure. In the embodiment of fig. 3, side extract line 127 is similarly replaced by line 126C, whereby a portion of the condensate from K/O121 can be combined with the decanter lean solvent in decanter lean solvent line 118 in combined line 118A. In contrast to the embodiment of fig. 2, in the propylene oxide separation system 100B of fig. 3, the organic phase in the organic phase outlet line 117 from the decanter 115 may be directed to a second solvent stripper 150. In embodiments such as that shown in fig. 3, the organic phase in organic phase outlet line 117 can be combined with the second extractive distillation column bottoms in second extractive distillation column bottoms line 142 prior to entering the second solvent stripper column 150.

Fig. 4 is a schematic diagram of a propylene oxide separation system 100C according to another embodiment of the present disclosure. In the embodiment of fig. 4, the liquid light purge in liquid light purge line 126B can be fed to decanter 115. In embodiments, the liquid light wash line 126B may be combined into the decanter feed line 114 prior to introduction to the decanter 115. Additionally, in the embodiment of fig. 4, the organic phase in organic phase outlet line 117 from decanter 115 can be directed to first extractive distillation column 120. In embodiments, as shown in fig. 4, the organic phase in organic phase outlet line 117 can be combined with the first extractive distillation column solvent entering first extractive distillation column solvent inlet line 129 prior to entering first extractive distillation column 120.

Fig. 5 is a schematic diagram of a propylene oxide separation system 100D according to another embodiment of the present disclosure. In the embodiment of fig. 5, the liquid light purge in liquid light purge line 126B can be fed to decanter 115. In embodiments, the liquid light wash lines in the liquid light wash line 126B may be combined into the decanter feed line 114 prior to introduction to the decanter 115. Additionally, in the embodiment of fig. 5, the organic phase in the organic phase outlet line 117 from the decanter 115 may be directed to a second solvent stripper 150. In embodiments such as in fig. 5, the organic phase in the organic phase outlet line 117 can be combined with the second extractive distillation column bottoms in the second extractive distillation column bottoms line 142 prior to entering the second solvent stripper column 150.

Feature/potential benefit

The systems and methods of the present disclosure provide for the removal of heavies from a crude PO stream as an upstream step in a PO purification process. In embodiments, the heavy removal is the first step in the PO purification process according to the present disclosure. In embodiments, removal of heavies via non-solvent distillation is the only distillation step upstream of the (first) extractive distillation in the PO purification process according to the present disclosure. In embodiments, the system of the present disclosure does not include a non-solvent distillation column upstream of the first extractive distillation column other than the heavy distillation column. In embodiments, the process according to the present disclosure does not include a non-solvent distillation, other than a heavy distillation column, upstream of the first extractive distillation. In embodiments, the downstream separation (e.g., the first extractive distillation column, the second extractive distillation column, or both) may be conducted at a lower temperature than a corresponding separation/unit of a similar system in the absence of upstream heavies removal of the present disclosure. In embodiments, the system of the present disclosure does not include a caustic mixer and/or a backwash tower as described in U.S. patent No. 9,593,090.

In embodiments, the total PO purge is the total PO in a combined stream of (a) the heavy purge bottoms extracted from the heavy distillation column 110 via the heavy purge bottoms line 102, (B) the light purge extracted from the first extractive distillation column 120 via the first extractive distillation column overhead vapor purge line 125A and the liquid light purge line 126B, (c) the light hydrocarbon purge extracted from the second solvent stripper column 150 via the second solvent stripper column overhead line 153, and (d) the aqueous phase purge extracted from the decanter 115 via the aqueous phase purge outlet line 116, which comprises less than or equal to 18, 17, 16, 15, 14, 13, 12, 11, 10, 9, 8, 7, 6, 5, 4, 3, 2, 1, 0.5, or 0.3 wt% of the total PO in the crude PO stream fed to the heavy distillation column 110 (i.e., the total PO in the crude PO fed to the heavy distillation column 110 via the crude PO inlet line 101). In embodiments, the system or method of the present disclosure is considered to be a reduced slope PO and the total PO wash is less than or equal to 18, 17.5, 17, 16.5, 16, 15.5, 15, 14.5, or 14 wt% of the total PO in the crude PO stream. In embodiments, the system or method of the present disclosure is considered to be a lower slope PO and the total PO wash is less than or equal to 8, 7, 6, 5, 4, 3, 2, 1, 0.5, 0.3, or 0.1 wt% of the total PO in the crude PO stream.

By positioning the non-solvent heavy distillation column prior to PO purification and removing heavy ends from its bottoms, a purer PO stream can be introduced to a subsequent extractive distillation column (e.g., first extractive distillation column 120). Unexpectedly, in embodiments, removal of the heavy fraction (which can remove aldehydes and/or aldehyde derivatives, such as, but not limited to, formaldehyde and formaldehyde derivatives) with the bottoms of the preliminary heavy fraction distillation column 110 can result in more efficient light removal (e.g., via the light purge overheads in the first extractive distillation column overhead vapor purge line 125A and the liquid light purge line 126B) in the extractive distillation column downstream of the heavy distillation column (e.g., in the first extractive distillation column 120). This can provide a convenience in the production of a purified PO product having the desired purity. In embodiments, the systems and methods disclosed herein provide for removing a purified PO product from a downstream extractive distillation column as an overhead/distillate fraction (e.g., as an overhead PO product stream in second extractive distillation column overhead line 143 from second extractive distillation column 140).

The systems and methods disclosed herein including upstream heavies removal may provide for reduced solvent flow in the front loop including the first extractive distillation column 120 and the first solvent stripper column 130 relative to conventional PO purification without heavies removal upstream of the (first) extractive distillation that removes light ends purge. In embodiments, such a reduced solvent flow may include, for example, a reduction in the volumetric flow rate of first solvent stripping bottoms line 132 of at least 30%, 40%, or 50%.

Upstream heavies removal in accordance with the present disclosure may enable the introduction of a crude PO stream having relatively high amounts of water and methanol, for example, directly to PO purification system 100 (e.g., directly to heavy distillation column 110).

The following examples merely illustrate the systems and methods of the present disclosure. Those skilled in the art will recognize many variations that are within the spirit of the disclosure and scope of the claims.