Acetylene Production Process with Solid Separation
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Solution Overview
Problem
Current processes for producing acetylene and synthesis gas by partial oxidation of hydrocarbons with oxygen face challenges in achieving high yields while complying with environmental regulations, as they result in emissions of hydrocarbons and require costly drying of solids, and existing solutions either reduce acetylene yield or lead to accumulation of soot, coke, and tar.
Innovation Solution
A continuous process where hydrocarbons and oxygen are preheated separately and mixed in a specific ratio, with partial oxidation occurring in a combustion chamber, followed by pre-quenching to 100-1000°C to separate 50-90% of solids, and subsequent cooling and washing to achieve efficient separation and recycling of process water, reducing soot content and enabling dry separation of solids.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Object-affected harmful factors
If an open process water system with cooling tower is used, then hydrocarbon emissions occur, but the system requires complex separation equipment and costly drying of solids
Solution Approach 1:
The invention extracts and separates solid particles (soot, coke, tar) from the process water stream using a centrifugal separator, removing the harmful solid component before discharge. This extraction approach eliminates the need for complex drying equipment while addressing the emissions problem.
Solution Approach 2:
The invention introduces an intermediary centrifugal separation step between the process water system and the environment. This intermediary device separates solids from water, allowing the liquid phase to be safely discharged while solids are removed, thus mediating between the process needs and environmental requirements.
2Object-affected harmful factors
If a closed process water system is used, then hydrocarbon accumulation occurs leading to polymerization and clogging, but the system avoids emissions
Solution Approach 1:
The invention continuously extracts accumulated hydrocarbons and solids from the process water using the centrifugal separator, preventing polymerization and clogging. This extraction mechanism maintains system reliability by removing problematic substances before they can cause failures.
Solution Approach 2:
The invention discards accumulated solids and hydrocarbons from the process water stream through centrifugal separation. By continuously removing these substances, the system maintains reliability and prevents the harmful effects of accumulation while still operating as a closed system.
3Reliability
If oxygen number is increased to reduce soot production, then acetylene yield decreases by 2 percentage points, but stationary operation can be guaranteed
Solution Approach 1:
The invention changes the operational parameters by implementing a two-stage quenching process with specific temperature control (first stage to 80-90°C, second stage to 20-40°C). This parameter optimization allows operation at higher oxygen numbers for stability while recovering acetylene yield through improved process control.
Solution Approach 2:
The invention applies preliminary cooling in the first quenching stage to 80-90°C before the second stage cooling. This preliminary action prepares the gas stream for more efficient acetylene recovery and separation in subsequent stages, thereby improving overall yield while maintaining operational stability.
4Quantity of substance
If solids are separated wet from process water, then separation is achieved, but costly drying equipment is required for commercial marketing
Solution Approach 1:
The invention extracts solids from process water using centrifugal separation, producing a concentrated solid stream that can be directly utilized or disposed of without requiring drying. This extraction approach eliminates the need for costly drying equipment while achieving effective solids removal.
Solution Approach 2:
The invention changes the separation approach from wet chemical methods to mechanical centrifugal separation. This parameter change in the separation mechanism achieves high solids removal efficiency while producing a dry solid stream that does not require additional drying equipment for commercial applications.
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
This process ensures high acetylene yield, compliance with environmental regulations by minimizing emissions, and allows for continuous operation without complex solid-liquid separation devices, while achieving efficient separation and retention of solid by-products, thus making the process more attractive and environmentally friendly.
Implementation Method 1
the first cracked gas stream I g is cooled in a pre-quench by injecting an aqueous quenching medium to a temperature in the range from 100 to 1000 ° C
Implementation Method 2
stream VI liq is evaporated in a proportion of 0.01 to 10% by weight, based on the total weight thereof, to obtain a purified process water stream VII liq
Implementation Method 3
partial oxidation of the hydrocarbons takes place, obtaining a first cracked gas stream I g
Implementation Method 4
in a combustion chamber, in which the partial oxidation of the hydrocarbons takes place
Data Source
AI summary
The invention relates to a continuous method for producing acetylenes and syngas by partially oxidizing hydrocarbons with oxygen. A first feed stream (1) containing one or more hydrocarbons and a second feed stream (2) containing oxygen are - mixed in a ratio of the mass flows of the second feed stream (2) to the first feed stream (1) corresponding to an oxygen number of less than or equal to 0.31, said streams being heated separately from each other, - and fed to a combustion chamber (FR) via a burner block (BR), the partial oxidation of the hydrocarbons being carried out in said combustion chamber, - thereby obtaining a first cracked gas stream Ig. The invention is characterized in that - the first cracked gas stream Ig is precooled to a temperature ranging from 100 to 1000 °C in a prequench region (H), thereby obtaining a second cracked gas stream IIg, - 50 to 90% of the solids contained in the second cracked gas stream IIg are separated therefrom in a solid-gas separating device (A), thereby obtaining a solid stream If and a third cracked gas stream IIIg, - the third cracked gas stream IIIg is cooled to 80 to 90 °C by injecting water in a total quench region (B), thereby obtaining a fourth cracked gas stream IVg and a first process water stream Iliq, - the fourth cracked gas stream IVg undergoes a fine separation of solids in one or more scrubbing devices (C, D), thereby obtaining one or more process water streams IIliq, IIIliq and a product gas stream VIg, - the process water streams Iliq, IIliq, IIIliq are merged into a combined process water stream IVliq, - the combined process water streamIVliq is partly recirculated, as stream Vliq, into the total quench region (B) and otherwise undergoes a cleaning process, as stream VIliq, by means of a partial evaporation process, thereby obtaining a cleaned process water stream VIIliq, - which is cooled by a recooling device (F), partially recycled, as stream VIIIliq, into the method, and otherwise discharged, as stream IXliq.