Two-Step Process for Feasible Conversion of Ethane to Aromatics: Concept and Demonstration

Abstract

Direct conversion of light alkanes, specifically ethane to aromatics, has been an important research goal for both academia and industry over the past several decades. Despite a significant research investment, there have been no major technical breakthroughs to date, due in large part to the inability to develop catalysts with satisfactory performance. This article proposes a two-step process concept for aromatics production from ethane that has the potential to address this impasse. Our process involves performing the dehydrogenation of ethane in a first step, followed by ethylene aromatization in a separate reactor. We begin by reviewing the major fundamental and technical hurdles associated with efforts to develop one-step processes and use this to show how our two-step process can overcome limitations in the reaction pathway, thermodynamics, and catalyst performance encountered in the one-step approach. We then describe catalyst validation, reactor design, and process economics to illustrate the value of our concept.