Circulating Catalyst Regeneration for Alkyl Bromide Conversion
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Current processes for converting natural gas to higher molecular weight hydrocarbons are limited by high capital and operating costs, and low carbon efficiencies, making them commercially unviable for widespread industry acceptance.
Innovation Solution
A process involving the reaction of alkyl bromides over a catalyst in a circulating catalyst reactor-regenerator system, where the catalyst is continuously or intermittently regenerated, allowing for the recovery of hydrocarbons and minimizing carbon loss, and a two-stage stripping unit is used to recover C6+ hydrocarbons before oxidative regeneration.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If conventional processes are used for converting natural gas to higher molecular weight hydrocarbons, then conversion can be achieved, but capital and operating costs are high and carbon efficiency is low
Solution Approach 1:
The patent implements a circulating catalyst system where the catalyst is continuously regenerated by removing coke deposits through combustion with air. This recovery and regeneration process maintains catalyst activity and prevents carbon loss, directly addressing the carbon efficiency problem while enabling continuous operation without frequent catalyst replacement
Solution Approach 2:
The patent establishes a continuous circulation system where the catalyst moves from the reaction zone to the regeneration zone and back, enabling uninterrupted conversion of natural gas to higher molecular weight hydrocarbons. This continuous operation eliminates downtime and maintains optimal conversion efficiency throughout the process
2Productivity
If conventional conversion processes are used, then hydrocarbon conversion can occur, but reactor volume and catalyst requirements are high
Solution Approach 1:
By continuously regenerating the catalyst through coke removal and recycling it back to the reaction zone, the system maintains high catalyst activity concentration. This recovery approach allows for reduced reactor volume while sustaining high productivity, as the same catalyst mass can be reused repeatedly without degradation
Solution Approach 2:
The patent optimizes reaction parameters including temperature, pressure, and catalyst circulation rate to maximize conversion efficiency within a compact reactor volume. By adjusting these parameters, the system achieves high productivity without requiring excessive reactor size
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 approach enables continuous reactor operation, reduces catalyst and reactor volume requirements, and enhances carbon efficiency by recovering valuable hydrocarbons, thereby making the conversion of natural gas to higher molecular weight hydrocarbons more economically viable.
Implementation Method 1
reacting at least alkyl bromides over a catalyst in at least one conversion reactor to produce at least an effluent stream comprising higher molecular weight hydrocarbons and hydrogen bromide
Implementation Method 2
contacting the portion of the catalyst with a stripping gas to displace hydrocarbons from the portion of the catalyst
Implementation Method 3
contacting the portion the catalyst with oxygen to form a regenerated catalyst by removal of coke
Data Source
AI summary
Process and system that include the conversion of alkyl bromides to higher molecular weight hydrocarbons in circulating catalyst reactor-regenerator systems. Alkyl bromides may be reacted over a catalyst in at least one conversion reactor to produce at least an effluent stream comprising higher molecular weight hydrocarbons and hydrogen bromide. A portion of the catalyst may be removed from the conversion reactor. The portion of the catalyst may be contacted with a stripping gas to displace hydrocarbons from the portion of the catalyst. The portion of the catalyst may be contacted a first inert gas. The portion of the catalyst may be contacted with oxygen to form a regenerated catalyst by removal of coke. The regenerated catalyst may be contacted with a second inert gas. At least a portion of the regenerated catalyst may be introduced into the conversion reactor.