Ambient Hydrocarbon Separation Using Adsorbent Beds
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Solution Overview
Problem
Existing hydrocarbon separation systems for gas pipeline compressor engines require cryogenic cooling to isolate methane and higher carbon chainlength hydrocarbons, necessitating the use of methanol injection to prevent hydrate formation, which is inefficient and costly.
Innovation Solution
A hydrocarbon separation system that uses adsorbent beds to segregate methane or ethane from higher carbon chainlength hydrocarbons at ambient temperatures, employing pressure swing adsorption (PSA) or temperature swing adsorption (TSA) processes, with an electronic controller to manage regeneration and flow direction based on breakthrough signals from sensors.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If cryogenic cooling is used to separate methane from higher carbon chainlength hydrocarbons, then separation effectiveness is improved, but energy consumption and system complexity increase
Solution Approach 1:
The patent changes the temperature parameter from cryogenic conditions to near-ambient temperatures, and changes the separation mechanism from thermal condensation to adsorption. The adsorbent material properties are optimized for selective adsorption of higher carbon chainlength hydrocarbons at elevated temperatures, eliminating the need for energy-intensive cooling while achieving effective separation.
Solution Approach 2:
The patent replaces the mechanical/thermal system (cryogenic cooling and condensation) with a chemical adsorption system. Instead of using temperature differential to condense hydrocarbons, the system uses adsorbent materials that selectively bind higher carbon chainlength hydrocarbons through molecular interactions, achieving separation without cryogenic equipment.
2Manufacturing precision
If cryogenic cooling is used to separate hydrocarbons, then separation effectiveness is improved, but device complexity increases due to methanol injection system
Solution Approach 1:
The patent extracts and eliminates the methanol injection system and associated hydrate prevention equipment from the cryogenic separation system. By using adsorption at near-ambient temperatures, the system removes the need for complex temperature control equipment, methanol storage and injection systems, and hydrate management infrastructure, significantly simplifying the overall装置.
Solution Approach 2:
The patent changes the operating temperature parameter from cryogenic to near-ambient conditions, which fundamentally alters the separation mechanism from thermal condensation to adsorption. This parameter change eliminates the need for complex cryogenic equipment and methanol injection systems, achieving effective separation with a much simpler apparatus.
3Use of energy by moving object
If adsorbent beds are used for separation at ambient temperature, then energy consumption is reduced, but separation effectiveness may worsen
Solution Approach 1:
The patent employs porous adsorbent materials with optimized pore structures and surface chemistries that provide high selectivity for higher carbon chainlength hydrocarbons. The porous structure increases the surface area for adsorption and creates size-exclusion effects that enhance separation effectiveness, allowing the system to achieve cryogenic-level separation at ambient temperatures without energy-intensive cooling.
Solution Approach 2:
The patent uses composite adsorbent materials that combine multiple functional components to achieve both high capacity and high selectivity for higher carbon chainlength hydrocarbons. The composite structure integrates materials with complementary properties, such as porous supports functionalized with selective binding groups, enabling effective separation at ambient temperatures with reduced energy consumption.
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 system effectively isolates methane or ethane without cryogenic cooling, reducing energy consumption and operational costs, while maintaining efficient separation and regeneration of adsorbent beds.
Implementation Method 1
The separator may be configured to isolate methane and/or ethane from propane, butane, isobutane and pentane and isopentane, and other higher carbon chainlength hydrocarbon molecules
Implementation Method 2
employing pressure swing adsorption (PSA) or temperature swing adsorption (TSA) processes
Implementation Method 3
employing pressure swing adsorption (PSA) or temperature swing adsorption (TSA) processes
Data Source
AI summary
A hydrocarbon separation system for an engine fuel supply system is disclosed. The hydrocarbon separation system may include an untreated gas conduit configured to transport a raw gas stream including methane, ethane and higher carbon chainlength hydrocarbon molecules. The system may also include a separator downstream of and fluidly coupled to the untreated gas conduit configured to segregate methane or ethane of the raw gas stream from the higher carbon chainlength hydrocarbon molecules of the raw gas stream. A treated gas conduit may be located downstream of and fluidly coupled to the separator and be configured to transport the methane or ethane of the raw gas stream away from the separator. Lastly, the system may include an electronic controller configured to receive a breakthrough signal and transmit a regeneration signal in response to the breakthrough signal.