Method and apparatus for regulating flame length in a partial oxidation reactor

Abstract

An apparatus (100, 200, 500) is provided that includes at least one burner (106, 208, 300) having a plurality of coaxial passages and a control system (502) for regulating a length of a flame (102, 206) for partial oxidation of a hydrocarbon feed in a reactor (104, 202, 508). The at least one burner (106, 208, 300) includes a first passage (108, 210, 302) for injecting an oxidant stream, a second passage (110, 212, 304) for injecting the hydrocarbon feed stream, and a third passage (112, 214, 306) for injecting a vortex gas stream into the hydrocarbon feed stream at a first velocity. The control system (502) regulates the length of the flame (102, 206) to have a constant flame shape and location by regulating the first velocity of the vortex gas that creates a vortex motion within the hydrocarbon feed stream.

Description

Technical Field

[0001] This disclosure generally relates to the partial oxidation of hydrocarbons, and more specifically to methods and apparatus for adjusting the flame length for the partial oxidation of hydrocarbon feedstocks in reactors used for syngas production. Background Technology

[0002] The partial oxidation of hydrocarbon feedstocks for syngas production is well-known in principle, and various different processes and apparatuses are known in principle in the prior art. Typically, this process is carried out at high reactor temperatures in the range of 1200°C–1500°C and pressures up to 100 bar. Known solutions describe processes and associated reactors for reacting hydrocarbon feedstocks with an oxidant stream within the reactor. The stream is injected into the reactor through a burner. Different apparatuses for injecting and mixing different streams (i.e., oxidant, hydrocarbon feedstock, and sometimes moderating agent) are disclosed in known solutions. As a moderating agent, carbon dioxide (CO2) or steam is often applied, fed separately into the reactor through separate channels within the burner, or mixed with one or more streams upstream of the burner. As an oxidant, air, oxygen-enriched air, or pure oxygen (>95 mol%) is typically applied. The hydrocarbon feed stream is a stream containing hydrocarbons such as methane or higher hydrocarbons or other molecules containing hydrogen and carbon (e.g., alcohols such as methanol, ethanol). This could also be a stream from an upstream primary reformer, containing hydrocarbons such as methane, ethane, ethylene, propane, or higher hydrocarbons such as benzene, toluene, and xylene, in addition to carbon monoxide (CO), hydrogen (H2), CO2, and water (H2O). Mixing of the hydrocarbon feedstock and oxidant typically takes place within the reactor, immediately adjacent to the injection nozzle. Strong mixing of the hydrocarbon feedstock and oxidant is preferred to achieve a high conversion of the hydrocarbon feedstock to syngas by minimizing oxidant consumption. Another known solution describes a coaxial burner in which different streams are guided in a common annular manner through burners with different channels and mixed externally. Mixing is achieved through different stream outlet velocities. In another known solution, in addition to pure coaxial injection of different streams, one or more streams can also be inclined at the nozzle outlet level toward the central axis of the burner-reactor arrangement. Other known solutions describe burners with fixed vortex devices utilizing blades. Known solutions also describe helical vortex chambers for hydrocarbon feedstocks, into which the stream is injected tangentially.

[0003] A disadvantage of fixed vortex devices via blades is that the vortex cannot be altered during operation. Therefore, flame length and shape are a consequence of the burner and reactor geometry, the volumetric flow velocity under operating conditions, and the chemical composition of the flow. Similar observations apply to non-vortex jet flames. Flame length and shape can be calculated using computational fluid dynamics (CFD) techniques. Furthermore, scientific papers provide general dependencies on flame length; for example, according to A. Schumaker et al., Proc. Comb. Inst. [Proceedings of the International Conference on Combustion] 32 (2009) 1655-1662, the stoichiometric flame length of a non-vortex coaxial jet burner is a function of the center injection diameter, the momentum ratio between the oxidizer and the hydrocarbon feedstock, and the molar stoichiometric fraction of the mixture. Recently, A. Degeneve et al. (Proceedings of the International Conference on Combustion, 2018, 37(4), 4563-4570, ISSN 1540-7489) reported that this dependence can be extended to configurations using vortex coaxial jets by introducing the geometric vortex number as an additional factor. Due to the need to increase the flexibility of mechanical equipment (not only through the control ratio, but also by changing the composition of the obtained syngas through different H2 / CO ratios), for example, different amounts of CO2 can be mixed into the hydrocarbon feed stream before the burner. This at least alters the momentum ratio of the different streams at the burner nozzle and thus results in different flame lengths and positions within the reactor. In extreme cases, this can lead to damage to the burner or refractory materials.

[0004] In addition to the drawbacks of a fixed geometry, vortex blades cause additional pressure drops. This additional pressure drop is particularly significant for low-pressure hydrocarbon feedstock streams originating from blast furnaces or primary reformers (e.g., fixed-bed or bubbling fluidized-bed reformers for biomass or waste reforming) that typically operate at slight overpressures of 50–3000 mbar. Furthermore, variations in the composition of the primary reforming gas feedstock are frequently observed, which can alter flame characteristics within subsequent partial oxidation (POX) units—changes that cannot be mitigated by fixed burner designs with static blades.

[0005] Therefore, it is necessary to address the aforementioned technical shortcomings in the prior art in order to adjust the flame length within the reactor during the partial oxidation of the feed stream. Summary of the Invention

[0006] This disclosure seeks to provide an efficient method and apparatus for adjusting the flame length for partially oxidizing hydrocarbon feed within a reactor. The object of this disclosure is to provide a solution that at least partially overcomes the problems encountered in the prior art, and to provide an improved method and apparatus for automatically adjusting the flame length to maintain a constant flame shape and position within a reactor for partially oxidizing hydrocarbon feed, thereby protecting the burner nozzle and refractory material from excessively high temperatures that could cause damage under varying operating conditions or hydrocarbon feed compositions. This object of the disclosure is achieved by the solutions provided in the appended independent claims. Advantageous embodiments of the disclosure are further defined in the dependent claims.

[0007] According to a first aspect, a method is provided for adjusting the flame length for partially oxidizing a hydrocarbon feed in a reactor, the method comprising: injecting an oxidant stream and the hydrocarbon feed into the reactor to generate the flame, wherein the oxidant stream and the hydrocarbon feed are coaxially injected into the reactor through a plurality of coaxial channels of at least one burner; injecting a vortex gas stream into the hydrocarbon feed stream at a first velocity, wherein the vortex gas is tangentially injected through at least one injection nozzle disposed within the plurality of coaxial channels to generate vortex motion within the hydrocarbon feed stream, wherein the first velocity of the vortex gas is determined using a control system based on a programmed parameter flame length function relating to at least one operating parameter of the reactor; and adjusting the flame length to have a constant flame shape and position within the reactor by adjusting the first velocity of the vortex gas stream generating the vortex motion in the hydrocarbon feed stream.

[0008] The method disclosed herein can automatically adjust the flame length to maintain a constant flame shape and position within a reactor for partially oxidized hydrocarbon feedstock, protecting the burner nozzle and refractory material from high temperatures that could cause damage under varying operating conditions or hydrocarbon feed composition. This method generates a stable, anchored flame, thereby minimizing the reactor size required for partially oxidized hydrocarbon feedstock. Another advantage of the method disclosed herein is that it can adjust the flame length to maintain a constant flame shape and position within the reactor based on the hydrocarbon feed composition required to achieve the desired syngas composition, reactor load, and oxidant dosage. Embodiments of this disclosure do not require a fixed burner configuration. Therefore, the flame length can be adjusted using a control system based on a programmed flame length function relating to at least one operating parameter of the reactor to maintain a constant flame shape and position within the reactor for partially oxidized hydrocarbon feedstock.

[0009] According to a second aspect, this disclosure provides an apparatus for adjusting the flame length for partially oxidizing a hydrocarbon feed in a reactor to produce syngas, the apparatus comprising: at least one burner including a plurality of coaxial channels including a first channel for injecting an oxidant stream into the reactor; a second channel for injecting the hydrocarbon feed stream into the reactor, wherein the injection of the hydrocarbon feed stream and the oxidant stream generates the flame within the reactor; and a third channel for injecting a vortex gas stream into the hydrocarbon feed stream at a first velocity, wherein the vortex gas is tangentially injected through at least one injection nozzle of the third channel to generate vortex motion within the hydrocarbon feed stream, wherein the at least one injection nozzle is fluidly connected to the second channel; and a control system that determines the first velocity of the vortex gas based on a programmed parameter flame length function relating to at least one operating parameter of the reactor, and adjusts the first velocity of the vortex gas generating vortex motion in the hydrocarbon feed stream to adjust the flame length to have a constant flame shape and position within the reactor.

[0010] The device disclosed herein can automatically adjust the flame length to maintain a constant flame shape and position within a reactor for partially oxidized hydrocarbon feed, protecting the burner nozzle and refractory material from high temperatures that could cause damage under varying operating conditions or hydrocarbon feed compositions. This method generates a stable, anchored flame, thereby minimizing the reactor size required for partially oxidized hydrocarbon feed. Furthermore, in various embodiments, the device can adjust the flame length to maintain a constant flame shape and position within the reactor based on the hydrocarbon feed composition, reactor load, and oxidant dosage required to achieve the desired syngas composition. Such a device configuration enables a constant flame shape without requiring a fixed burner configuration.

[0011] The embodiments disclosed herein eliminate the aforementioned disadvantages of existing known methods for regulating the flame length for partially oxidized hydrocarbon feed within a reactor. An advantage of the embodiments according to this disclosure is that they can automatically regulate the flame length to maintain a constant flame shape and position within the reactor for partially oxidized hydrocarbon feed, protecting the burner nozzle and refractory material from excessively high temperatures that could cause damage under varying operating conditions or hydrocarbon feed compositions. These embodiments can produce a stable, anchored flame, thereby minimizing the reactor size required for the partially oxidized hydrocarbon feed flow. Further aspects, advantages, features, and objectives of this disclosure will become apparent from the accompanying drawings, which are interpreted in conjunction with the following detailed description of exemplary embodiments, along with the appended claims. It should be appreciated that the features of this disclosure can be combined in various combinations without departing from the scope of this disclosure as defined by the appended claims. Attached Figure Description

[0012] The above-described invention and the following detailed description of exemplary embodiments will be better understood when read in conjunction with the accompanying drawings. Exemplary constructions of this disclosure are illustrated in the drawings to illustrate the present disclosure. However, this disclosure is not limited to the specific methods and means disclosed herein. Furthermore, those skilled in the art will understand that the drawings are not drawn to scale. Where possible, the same elements are represented by the same numbers. Embodiments of this disclosure will now be described by way of example only with reference to the following figures, in which:

[0013] Figure 1 This is a schematic diagram of an apparatus for adjusting the flame length for partially oxidizing hydrocarbon feed within a reactor, according to embodiments of this disclosure.

[0014] Figure 2 This is a schematic diagram of a device having at least two different thermocouples for adjusting the flame length for partially oxidizing hydrocarbon feed in a reactor, according to an embodiment of this disclosure.

[0015] Figure 3 This is a schematic diagram of the arrangement of at least one burner of a device for adjusting the flame length for partially oxidizing hydrocarbon feed in a reactor, according to an embodiment of this disclosure.

[0016] Figure 4 According to the embodiments disclosed herein Figure 3 A schematic diagram of a cross-sectional view AA of at least one burner having at least one injection nozzle for tangentially injecting swirling gas into a hydrocarbon feed stream;

[0017] Figure 5 This is a schematic diagram of an apparatus for automatically adjusting the flame length for partially oxidizing hydrocarbon feed within a reactor, according to embodiments of this disclosure; and

[0018] Figure 6 This is a flowchart illustrating a method for adjusting the flame length for partially oxidizing hydrocarbon feed within a reactor, according to embodiments of this disclosure. Detailed Implementation

[0019] The following detailed description illustrates embodiments of this disclosure and ways in which it can be implemented. Although some models for carrying out this disclosure have been disclosed, those skilled in the art will recognize that other embodiments for carrying out or practicing this disclosure are also possible.

[0020] According to a first aspect, a method is provided for adjusting the flame length for partially oxidizing a hydrocarbon feed in a reactor, the method comprising: injecting an oxidant stream and the hydrocarbon feed into the reactor to generate the flame, wherein the oxidant stream and the hydrocarbon feed are coaxially injected into the reactor through a plurality of coaxial channels of at least one burner; injecting a vortex gas stream into the hydrocarbon feed stream at a first velocity, wherein the vortex gas is tangentially injected through at least one injection nozzle disposed within the plurality of coaxial channels to generate vortex motion within the hydrocarbon feed stream, wherein the first velocity of the vortex gas is determined using a control system based on a programmed parameter flame length function relating to at least one operating parameter of the reactor; and adjusting the flame length to have a constant flame shape and position within the reactor by adjusting the first velocity of the vortex gas stream generating the vortex motion in the hydrocarbon feed stream.

[0021] The advantage of this embodiment is that the method can automatically adjust the flame length to maintain a constant flame shape and position within the reactor for partially oxidized hydrocarbon feed, protecting the burner nozzle and refractory material from excessively high temperatures that could cause damage under varying operating conditions or hydrocarbon feed compositions. This method generates a stable, anchored flame, thereby minimizing the reactor size required for partially oxidized hydrocarbon feed. Another advantage of the method according to this disclosure is that it can adjust the flame length to maintain a constant flame shape and position within the reactor based on the hydrocarbon feed composition required to achieve the desired syngas composition, reactor load, and oxidant dosage. The embodiments of this disclosure do not require a fixed burner configuration. Therefore, the flame length can be adjusted using a control system based on a programmed parameter flame length function relating to at least one operating parameter of the reactor to maintain a constant flame shape and position within the reactor for partially oxidized hydrocarbon feed.

[0022] When the hydrocarbon feed stream and oxidant are coaxially injected into the reactor through multiple coaxial channels of at least one burner, a flame is generated within the reactor due to combustion. A vortex gas stream is injected tangentially at a first velocity through at least one injection nozzle disposed within the multiple coaxial channels to generate vortex motion within the hydrocarbon feed. The vortex gas stream can be injected at a volumetric flow rate or a mass flow rate used to generate vortex motion in the hydrocarbon feed stream. Optionally, the first velocity of the volumetric flow rate is the same for each known injection area.

[0023] Hydrocarbon feedstocks include hydrocarbons such as methane, natural gas, liquefied natural gas (LNG), propane-butane mixtures, liquefied petroleum gas (LPG), higher hydrocarbons or mixtures such as benzene, toluene, xylene, naphtha, cracked oil, or other hydrogen and carbon-containing molecules such as methane, ethane, ethylene, methanol, or ethanol. The oxidant can be air, oxygen-enriched air, or pure oxygen (>95 mol%). At least one burner side facing the hot atmosphere inside the reactor can be additionally water-cooled.

[0024] In an embodiment, the method further includes injecting a moderating gas stream through the plurality of coaxial channels of at least one burner, wherein the moderating gas is injected through a channel between the oxidant stream and the hydrocarbon feed stream. The moderating gas is a cooling gas, and the channel for injecting the moderating gas has a bottom end in fluid communication with the reactor. The moderating gas stream acts as a shielding flow between the oxidant stream and the hydrocarbon feed stream.

[0025] In an embodiment, the first velocity of the swirling gas is adjusted based on at least one of the composition of the hydrocarbon feed required to achieve the desired syngas composition, the reactor load, or the amount of the oxidant. The hydrocarbon feed may include different compositions.

[0026] In an embodiment, the reactor operating parameters include at least one of the following: the mass flow rate and volumetric flow rate of the oxidant and the hydrocarbon feed; temperature and pressure; the size of the at least one burner; the size of the plurality of coaxial channels; or the size of the at least one injection nozzle.

[0027] In embodiments, these programmed parameter flame length functions include a correlation function or table of the flame length with respect to at least one operating parameter of the reactor. The correlation function can be obtained from the parameterization of a computational fluid dynamics (CFD) simulation involving the simulation of fluid motion using numerical methods. The correlation function can be obtained using a proportional relationship of the flame length with respect to a proportionality law (e.g., as described in A. Degeneve et al., Proc. Comb. Inst. [Proceedings of the International Conference on Combustion], 2018, 37(4), 4563-4570, ISSN 1540-7489).

[0028] In one embodiment, the at least one burner includes multiple coaxial channels with an open bottom in fluid communication with the reactor. In another embodiment, at least one injection nozzle is in fluid connection with the hydrocarbon feed stream.

[0029] In embodiments, the vortex gas is a moderating gas, exhaust gas, or purge gas of a downstream synthesis machinery operating under high pressure, and the vortex gas comprises a pressure higher than that of the hydrocarbon feed stream. The pressure of the vortex gas is optionally 0.1-5 bar higher than the pressure of the hydrocarbon feed stream, typically 100-500 mbar higher. The moderating gas may include steam or carbon dioxide (CO2). The CO2 gas may advantageously be taken from a syngas scrubbing stage arranged downstream of the syngas produced by a partial oxidation (POX) burner. CO2 can be separated from the syngas using a cryogenic methanol wash process, which uses cold methanol as a solvent to separate CO2 from the syngas. In a cryogenic methanol wash process, cold methanol at a temperature of approximately -40°C to -62°C is used. The exhaust / purge gas may be a methanol purge gas. The exhaust / purge gas may be a purge gas from a Fischer-Tropsch process, which involves a multi-step reaction that converts a mixture of hydrogen (H2) and carbon monoxide (CO) into aliphatic products.

[0030] Vortex gas can be any gas stream that, under operating conditions, has high pressure and high volumetric flow rate to obtain the desired vortex in the hydrocarbon feed and does not react with the hydrocarbon feed under injection conditions. Typically, but not limited to, vortex gas streams originate from gas purification steps. A vortex gas stream can be, for example, a compressed CO2-rich stream from an acid gas removal unit utilizing an amine solvent or cold methanol. Vortex gas can be methanol tail gas. Vortex gas can be tail gas from a Fischer-Tropsch process, which involves a multi-step reaction that converts a mixture of H2 and CO into aliphatic products at significantly higher pressures compared to the hydrocarbon feed stream. Unwanted excess vortex gas, which is not required to achieve the desired vortex, can be injected upstream into the hydrocarbon feed such that no vortex is generated. Typically, excess vortex gas is injected upstream through a second channel of at least one burner.

[0031] According to a second aspect, this disclosure provides an apparatus for adjusting the flame length for partially oxidizing a hydrocarbon feed in a reactor to produce syngas, the apparatus comprising: at least one burner including a plurality of coaxial channels including a first channel for injecting an oxidant stream into the reactor; a second channel for injecting the hydrocarbon feed stream into the reactor, wherein the injection of the hydrocarbon feed stream and the oxidant stream generates the flame within the reactor; and a third channel for injecting a vortex gas stream into the hydrocarbon feed stream at a first velocity, wherein the vortex gas is tangentially injected through at least one injection nozzle of the third channel to generate vortex motion within the hydrocarbon feed stream, wherein the at least one injection nozzle is fluidly connected to the second channel; and a control system that determines the first velocity of the vortex gas based on a programmed parameter flame length function relating to at least one operating parameter of the reactor, and adjusts the first velocity of the vortex gas generating vortex motion in the hydrocarbon feed stream to adjust the flame length to have a constant flame shape and position within the reactor.

[0032] The device disclosed herein can automatically adjust the flame length to maintain a constant flame shape and position within a reactor for partially oxidized hydrocarbon feed, protecting the burner nozzle and refractory material from high temperatures that could cause damage under varying operating conditions or hydrocarbon feed compositions. This method generates a stable, anchored flame, thereby minimizing the reactor size required for partially oxidized hydrocarbon feed. Furthermore, in various embodiments, the device can adjust the flame length to maintain a constant flame shape and position within the reactor based on the hydrocarbon feed composition, reactor load, and oxidant dosage required to achieve the desired syngas composition. Such a device configuration enables a constant flame shape without requiring a fixed burner configuration.

[0033] Hydrocarbon feedstocks include hydrocarbons such as methane, natural gas, liquefied natural gas (LNG), propane-butane mixtures, liquefied petroleum gas (LPG), higher hydrocarbons or mixtures such as benzene, toluene, xylene, naphtha, cracked oil, or other hydrogen and carbon-containing molecules such as methane, ethane, ethylene, methanol, or ethanol. The oxidant can be air, oxygen-enriched air, or pure oxygen (>95 mol%). At least one burner side facing the hot atmosphere inside the reactor can be additionally water-cooled.

[0034] In one embodiment, the control system, configured to determine a first velocity of the swirling gas based on a programmed parameter flame length function relating to at least one operating parameter of the reactor, includes control devices communicating with a distributed control system (DCS). In another embodiment, the control system is integrated into the distributed control system (DCS).

[0035] In one embodiment, at least one burner further includes a fourth channel for injecting a moderating gas stream, wherein the fourth channel is located between the first and second channels. The moderating gas is a cooling gas, and the channel for injecting the moderating gas has a bottom end in fluid communication with the reactor. The moderating gas stream acts as a shielding flow between the oxidant stream and the hydrocarbon feed stream.

[0036] In one embodiment, the control system adjusts the first velocity of the swirling gas based on at least one of the composition of the hydrocarbon feed required to achieve the desired syngas composition, the reactor load, or the amount of oxidant. The hydrocarbon feed may include different compositions.

[0037] In an embodiment, the reactor operating parameters include at least one of the following: the mass flow rate and volumetric flow rate of the oxidant and the hydrocarbon feed; temperature and pressure; the size of the at least one burner; the size of the plurality of coaxial channels; or the size of the at least one injection nozzle.

[0038] In embodiments, these programmed parameter flame length functions include a correlation function or table of the flame length with respect to the operating parameters of the reactor. The correlation function can be obtained from the parameterization of a computational fluid dynamics (CFD) simulation involving numerical methods to model fluid dynamics. The correlation function can be obtained using the proportional relationship of the flame length with respect to a proportionality law, as described in A. Degeneve et al., Proc. Comb. Inst. [Proceedings of the International Conference on Combustion], 2018, 37(4), 4563-4570, ISSN 1540-7489.

[0039] In one embodiment, the at least one burner includes multiple coaxial channels with an open bottom in fluid communication with the reactor. In another embodiment, at least one injection nozzle includes tangential injection openings uniformly distributed within a third channel. Swirling gas is supplied by separate openings and flows to the coaxially arranged third channel, which uniformly distributes the tangential injection openings fluidly connected to the second channel. The tangential injection openings may include guide vanes to effectively guide the swirling gas flow through at least one injection nozzle to generate vortex motion in the hydrocarbon feed stream.

[0040] In one embodiment, the reactor includes a syngas outlet for the partial oxidation of hydrocarbon feedstock within the reactor, wherein the syngas outlet is located at the bottom of the reactor. In another embodiment, at least one burner is located at the top of the reactor.

[0041] In one embodiment, the device includes at least two distinct thermocouples located at different axial heights within the reactor to indicate the length and position of the flame to regulate the initial velocity of the swirling gas. The at least two distinct thermocouples may be positioned adjacent to the refractory wall of the reactor, thus making direct contact with the reactor. The device may also include multi-point thermocouples located within the reactor, configured to measure temperature at different locations along the length of the sensor.

[0042] In this embodiment, the hydrocarbon feed is obtained from a primary reformer operating at low pressure. The hydrocarbon feed from the upstream primary reformer includes, in addition to CO, H2, CO2, and H2O, hydrocarbons such as methane, ethane, ethylene, or higher hydrocarbons such as benzene, toluene, and xylene.

[0043] In this embodiment, the swirling gas is a moderating gas, exhaust gas, purge gas, or tail gas from a downstream synthesis machinery operating under high pressure. The moderating gas may include steam or CO2. The CO2 gas may advantageously be taken from a syngas scrubbing stage arranged downstream of the syngas produced by a partial oxidation (POX) burner. CO2 can be separated from the syngas using a cryogenic methanol scrubbing process that uses cold methanol as a solvent. In the cryogenic methanol scrubbing process, cold methanol at a temperature of approximately -40°C to -62°C is used. The exhaust / purge gas may be a methanol purge gas. Alternatively, the exhaust / purge gas may be a purge gas from a Fischer-Tropsch process, which involves a multi-step reaction that converts a mixture of H2 and CO into aliphatic products.

[0044] Vortex gas can be any gas stream that, under operating conditions, has high pressure and high volumetric flow rate to obtain the desired vortex in the hydrocarbon feed and does not react with the hydrocarbon feed under injection conditions. Typically, but not limited to, vortex gas streams originate from gas purification steps. A vortex gas stream can be, for example, a compressed CO2-rich stream from an acid gas removal unit utilizing an amine solvent or cold methanol. Vortex gas can be methanol tail gas. Vortex gas can be tail gas from a Fischer-Tropsch process, which involves a multi-step reaction that converts a mixture of H2 and CO into aliphatic products at significantly higher pressures compared to the hydrocarbon feed stream. Unwanted excess vortex gas, which is not required to achieve the desired vortex, can be injected upstream into the hydrocarbon feed such that no vortex is generated. Typically, excess vortex gas is injected upstream through a second channel of at least one burner.

[0045] In an embodiment, the swirling gas has a pressure 0.1-5 bar higher than that of the hydrocarbon feed stream, preferably 0.1-0.5 bar.

[0046] Detailed description of the attached figures

[0047] Figure 1This is a schematic diagram of an apparatus 100 for adjusting the length of a flame 102 used to partially oxidize a hydrocarbon feed within a reactor 104, according to an embodiment of this disclosure. The apparatus 100 includes at least one burner 106 comprising a plurality of coaxial channels. The at least one burner 106 includes a first channel 108 for injecting an oxidant stream into the reactor 104. The apparatus 100 includes a second channel 110 for injecting a hydrocarbon feed stream into the reactor 104. The injection of the hydrocarbon feed stream and the oxidant stream generates a flame 102 within the reactor 104. The at least one burner 106 includes a third channel 112 for injecting a swirling gas stream into the hydrocarbon feed stream at a first velocity. The swirling gas is tangentially injected through at least one injection nozzle 114 of the third channel 112 to generate vortex motion in the hydrocarbon feed stream. The at least one injection nozzle 114 is fluidly connected to the second channel 110. The apparatus 100 includes a control system that determines a first velocity of the swirling gas based on a programmed parameter flame length function relating to at least one operating parameter of the reactor, and adjusts the first velocity of the swirling gas, which generates vortex motion in the hydrocarbon feed stream, to adjust the length of the flame 102 to have a constant flame shape and position within the reactor 104. The apparatus 100 includes an outlet 116 for syngas, which is generated by the partial oxidation of the hydrocarbon feed in the reactor 104.

[0048] Figure 2This is a schematic diagram of an apparatus 200 having at least two different thermocouples 204A-D for adjusting the length of a flame 206 used for partially oxidizing a hydrocarbon feed within a reactor 202, according to embodiments of this disclosure. The apparatus 200 includes at least one burner 208 comprising a plurality of coaxial channels. The at least one burner 208 includes a first channel 210 for injecting an oxidant stream into the reactor 202. The apparatus 200 includes a second channel 212 for injecting a hydrocarbon feed stream into the reactor 202. The injection of the hydrocarbon feed stream and the oxidant stream generates a flame 206 within the reactor 202. The at least one burner 208 includes a third channel 214 for injecting a swirling gas stream into the hydrocarbon feed stream at a first velocity. The swirling gas is tangentially injected through at least one injection nozzle 216 of the third channel 214 to generate vortex motion in the hydrocarbon feed stream. The at least one injection nozzle 216 is fluidly connected to the second channel 212. The apparatus 200 includes at least two distinct thermocouples 204A-D located at different axial heights within the reactor 202 to indicate the length and position of the flame 206 to regulate the initial velocity of the swirling gas. The apparatus 200 includes a control system that determines the initial velocity of the swirling gas based on a programmed parameter, a flame length function, relating to at least one operating parameter of the reactor, and regulates the initial velocity of the swirling gas, which generates vortex motion in the hydrocarbon feed stream, to regulate the length of the flame 206 to maintain a constant flame shape and position within the reactor 202. The apparatus 200 includes an outlet 218 for syngas produced by the partial oxidation of the hydrocarbon feed in the reactor 202.

[0049] Figure 3 This is a schematic diagram of the arrangement of at least one burner 300 of an apparatus for adjusting the flame length for partially oxidizing a hydrocarbon feed within a reactor, according to embodiments of the present disclosure. At least one burner 300 includes a first channel 302 for injecting an oxidant stream into the reactor. The apparatus includes a second channel 304 for injecting a hydrocarbon feed stream into the reactor. The injection of the hydrocarbon feed stream and the oxidant stream generates a flame within the reactor. At least one burner 300 includes a third channel 306 for injecting a swirling gas stream into the hydrocarbon feed stream at a first velocity. The swirling gas is tangentially injected through at least one injection nozzle 308 of the third channel 306 to generate vortex motion in the hydrocarbon feed stream. At least one injection nozzle 308 is fluidly connected to the second channel 304.

[0050] Figure 4 According to the embodiments disclosed herein Figure 3A schematic cross-sectional view AA of at least one burner 300 is provided, the burner having at least one injection nozzle 308A-D for tangentially injecting swirling gas into a hydrocarbon feed stream. At least one burner 300 includes a plurality of coaxial channels. At least one burner 300 includes a first channel 302 for injecting an oxidant stream into the reactor. At least one burner 300 includes a second channel 304 for injecting a hydrocarbon feed stream into the reactor. The injection of the hydrocarbon feed stream and the oxidant stream generates a flame within the reactor. At least one burner 300 includes a third channel 306 for injecting a swirling gas stream into the hydrocarbon feed stream at a first velocity. The swirling gas is tangentially injected through at least one injection nozzle 308A-D in the third channel 306 to generate swirling motion in the hydrocarbon feed stream. At least one injection nozzle 308A-D is fluidly connected to the second channel 304.

[0051] Figure 5This is a schematic diagram of an apparatus for automatically adjusting the flame length for partially oxidizing a hydrocarbon feed in a reactor, according to an embodiment of this disclosure. Apparatus 500 includes a control system 502 that automatically controls the apparatus 500 to adjust the flame length for partially oxidizing the hydrocarbon feed in the reactor. A hydrocarbon feed is received from a primary reformer 504 operating at low pressure. The hydrocarbon feed is analyzed and its temperature and volumetric flow rate are measured, then it is directed to reactor 508 for partial oxidation of the hydrocarbon feed with an oxidant. An oxidant is received from, for example, an air separation unit or a storage tank 506. The oxidant is measured and adjusted according to the temperature and volumetric flow rate of the hydrocarbon feed, then directed to reactor 508. A vortex gas stream is received from a downstream synthesis process 512 operating at high pressure. The temperature and volumetric flow rate of the vortex gas are measured, then it is directed into the hydrocarbon feed stream. Apparatus 500 includes a flow control valve 510 for regulating the flow rate of the vortex entering the hydrocarbon feed stream. Apparatus 500 includes an actuator 514 for the flow control valve 510. The control system 502 determines a first velocity of the swirling gas based on a programmed parameter flame length function relating to at least one operating parameter of the reactor. This at least one operating parameter includes at least one of the hydrocarbon feed composition required to achieve the desired syngas composition, the reactor load, or the amount of oxidant. The control system 502 regulates the first velocity of the swirling gas, which generates vortex motion within the hydrocarbon feed stream, to regulate the flame length to maintain a constant flame shape and position within the reactor 508. The device 500 includes at least one flow indicator (FI) for indicating the volumetric flow rates of the hydrocarbon feed, oxidant, and swirling gas entering the control system 502. The device 500 includes at least one temperature indicator (TI) for indicating the temperature of the hydrocarbon feed, oxidant, and swirling gas entering the control system 502. The device 500 includes a flow indicator and controller (FIC) that has an indicator function to indicate the oxidant flow rate entering the control system 502, and the control system 502 sends signals to adjust the setpoints of the flow indicator and controller (FIC) to regulate the oxidant flow rate entering the reactor 508 based on measurements of the hydrocarbon feed volumetric flow rate, composition, temperature, and pressure. The vortex gas flow rate is automatically regulated by opening a flow control valve 510 leading to the hydrocarbon feed supply line before at least one burner.

[0052] Figure 6This is a flowchart illustrating a method for adjusting the flame length for partially oxidizing a hydrocarbon feed in a reactor according to embodiments of this disclosure. In step 602, an oxidant stream and a hydrocarbon feed are injected into the reactor to generate a flame. The oxidant stream and the hydrocarbon feed are coaxially injected into the reactor through multiple coaxial channels of at least one burner. In step 604, a vortex gas stream is injected into the hydrocarbon feed stream at a first velocity. The vortex gas is tangentially injected through at least one injection nozzle disposed within the multiple coaxial channels to generate vortex motion within the hydrocarbon feed stream. The first velocity of the vortex gas is determined using a control system based on a programmed parameter flame length function relating to at least one operating parameter of the reactor. In step 606, the flame length is adjusted to have a constant flame shape and position within the reactor by adjusting the first velocity of the vortex gas stream that generates vortex motion in the hydrocarbon feed stream.

[0053] Modifications may be made to embodiments of the disclosure described above without departing from the scope of the disclosure as defined by the appended claims. Expressions such as “comprising,” “including,” “incorporated,” “having,” and “is” used to describe and claim this disclosure are intended to be interpreted in a non-exclusive manner, allowing for the presence of items, components, or elements not explicitly described. Singular references are also interpreted to refer to the plural.

Claims

1. A method for adjusting the length of a flame used for partially oxidizing a hydrocarbon feed in a reactor, characterized in that, The method includes: An oxidant stream and a hydrocarbon feed stream are injected into a reactor to generate a flame, wherein the oxidant stream is injected into the reactor through a first channel of a plurality of coaxial channels of at least one burner, and the hydrocarbon feed stream is injected into the reactor through a second channel of the plurality of coaxial channels of the at least one burner. A stream of swirling gas is injected into the hydrocarbon feed stream at a first velocity, wherein the swirling gas is tangentially injected through at least one injection nozzle disposed in a third channel of the plurality of coaxial channels to generate swirling motion within the hydrocarbon feed stream, wherein the first velocity of the swirling gas is determined using a control system (502) based on a programmed parameter flame length function relating to at least one operating parameter of the reactor; and The length of the flame is adjusted by regulating the first velocity of the vortex gas flow that generates the vortex motion in the hydrocarbon feed stream to maintain a constant flame shape and position within the reactor. The vortex gas is a gas that generates the desired vortex in the hydrocarbon feed and does not react with the hydrocarbon feed under injection conditions.

2. The method as described in claim 1, wherein, The method further includes injecting a moderating gas containing vapor or CO2 through the plurality of coaxial channels of at least one burner, wherein the moderating gas is injected through a channel between the flow of the oxidant and the flow of the hydrocarbon feed.

3. The method as described in claim 1 or 2, wherein, The first velocity of the swirling gas is adjusted based on at least one of the composition of the hydrocarbon feed required to achieve the desired syngas composition, the load on the reactor, or the amount of the oxidant.

4. The method as described in claim 1 or 2, wherein, The operating parameters of the reactor include at least one of the following: the mass flow rate and volumetric flow rate of the oxidant and the hydrocarbon feed; the temperature and pressure; the size of the at least one burner; the size of the plurality of coaxial channels; or the size of the at least one injection nozzle.

5. The method as described in claim 1 or 2, wherein, These programmed parameter flame length functions include a function or table relating the flame length to at least one operating parameter of the reactor.

6. The method as described in claim 1 or 2, wherein, The at least one burner has multiple coaxial channels including an open bottom that is in fluid communication with the reactor.

7. The method as described in claim 1 or 2, wherein, The at least one injection nozzle is fluidly connected to the flow of the hydrocarbon feed.

8. The method as claimed in claim 1 or 2, wherein, The vortex gas is a moderating gas, exhaust gas, or purge gas in a downstream synthetic machinery operating under high pressure. The moderating gas contains vapor or CO2, and the vortex gas has a pressure 0.1-5 bar higher than the flow pressure of the hydrocarbon feed.

9. An apparatus for adjusting the length of a flame used for partially oxidizing a hydrocarbon feed in a reactor to produce syngas, characterized in that, The device includes: At least one burner includes a plurality of coaxial channels, which include: The oxidant is injected into the first channel of the reactor; A stream of hydrocarbon feed is injected into a second channel of the reactor, wherein the injection of the hydrocarbon feed stream and the oxidant stream generates a flame within the reactor; and A stream of swirling gas is injected at a first velocity into a third channel of the hydrocarbon feed stream, wherein the swirling gas is tangentially injected through at least one injection nozzle in the third channel to generate swirling motion within the hydrocarbon feed stream, wherein the at least one injection nozzle is fluidly connected to the second channel. The vortex gas is a gas that obtains the desired vortex in the hydrocarbon feed and does not react with the hydrocarbon feed under injection conditions; Control system (502), the control system The first velocity of the swirling gas is determined based on a programmed parameter flame length function relating to at least one operating parameter of the reactor; and The first velocity of the vortex gas, which generates vortex motion within the hydrocarbon feed stream, is adjusted to regulate the length of the flame so as to have a constant flame shape and position within the reactor.

10. The device as claimed in claim 9, wherein, The at least one burner further includes a fourth channel for injecting a moderating gas, the moderating gas comprising vapor or CO2, wherein the fourth channel is located between the first channel and the second channel.

11. The device as claimed in claim 9 or 10, wherein, The control system (502) adjusts the first velocity of the swirling gas based on at least one of the composition of the hydrocarbon feed required to achieve the desired synthesis gas composition, the load of the reactor, or the amount of the oxidant.

12. The device as claimed in claim 9 or 10, wherein, The operating parameters of the reactor include at least one of the following: the mass flow rate and volumetric flow rate of the oxidant and the hydrocarbon feed; the temperature and pressure; the size of the at least one burner; the size of the plurality of coaxial channels; or the size of the at least one injection nozzle.

13. The device as claimed in claim 9 or 10, wherein, These programmed parameter flame length functions include relevant functions or tables for the flame length based on the operating parameters of the reactor.

14. The device as claimed in claim 9 or 10, wherein, The at least one burner has multiple coaxial channels including an open bottom that is in fluid communication with the reactor.

15. The device as claimed in claim 9 or 10, wherein, The at least one injection nozzle includes tangential injection openings evenly distributed within the third channel.

16. The device as claimed in claim 9 or 10, wherein, The reactor includes an outlet for syngas produced by the partial oxidation of the hydrocarbon feed in the reactor, wherein the outlet for syngas is located at the bottom or underside of the reactor.

17. The device as claimed in claim 9 or 10, wherein, At least one burner is located at the top of the reactor.

18. The device as claimed in claim 9 or 10, wherein, The device includes at least two different thermocouples located at different axial heights inside the reactor to indicate the length and position of the flame in order to regulate the initial velocity of the swirling gas.

19. The device as claimed in claim 9 or 10, wherein, The hydrocarbon feed is obtained from a primary reformer (504) operating at low pressure.

20. The device as claimed in claim 9 or 10, wherein, The vortex gas is a moderating gas, exhaust gas, purge gas, or tail gas from a downstream synthetic machinery operating under high pressure, wherein the moderating gas contains vapor or CO2.

21. The device as claimed in claim 9 or 10, wherein, The swirling gas has a pressure 0.1-5 bar higher than that of the hydrocarbon feed stream.

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