Exploiting diluted bioethanol solutions for the production of ethylene: Preliminary process design and heat integration

Several activity tests on a zeolite-based catalyst for the ethanol to ethylene dehydration reaction are used to outline the stoichiometry of 4 reactions describing the observed outcome. The heat and mass balances of a reactor were calculated. The thermal input was mainly sustained with a standard product-to-feed heat exchange. Upstream, two possible strategies of ethanol-water beer concentration were compared, namely a single stage flash and a small column, yielding respectively a 3:1 water:ethanol mixture and a slightly diluted azeotrope. The external heat input needed for the separation unit, the feed heating up to the reaction temperature and the reaction upkeep are compared. A flow diagram for the hot utility is then designed, converting part of the water of the beer into superheated steam that gives also electric power. The conceptual design of an ethanol to ethylene plant is therefore available to exploit bioethanol solution with different water/ethanol ratios, with different ethanol purification routes with variable heat input and energy recovery.