Aromatic Hydrocarbon Production via Segmented Reactors
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Solution Overview
Problem
Current methods for producing aromatic hydrocarbons from natural gas are inefficient due to significant losses as by-products, particularly in the conversion process from methane to synthesis gas and subsequent production of aromatic compounds.
Innovation Solution
The method involves using two consecutively-connected reactors, a low-temperature isothermal reactor and a high-temperature adiabatic reactor, with a stabilization unit, and recycling hydrogen-containing gas to adjust the synthesis gas ratio, employing specific catalyst compositions and heat management techniques to enhance yield and efficiency.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If a single reactor is used for converting methanol to aromatic hydrocarbons, then the process is simpler, but the yield of aromatic hydrocarbons is lower due to significant losses as by-products
Solution Approach 1:
The conversion process is divided into two separate reactors: a first reactor for initial conversion of methanol to aromatic and aliphatic hydrocarbons, and a second reactor for further conversion of aliphatic hydrocarbons to aromatic hydrocarbons. This segmentation allows each reactor to be optimized for specific reactions, reducing by-product losses and increasing overall yield of aromatic hydrocarbons.
2Productivity
If hydrogen-containing gas is not recycled, then the process is simpler, but the synthesis gas ratio cannot be optimized, reducing production efficiency
Solution Approach 1:
Hydrogen-containing gas from the conversion process is recycled back to the synthesis gas production unit. This feedback loop allows for optimization of the synthesis gas composition (H2:CO ratio of 1.8-2.3:1), ensuring optimal conditions for methanol synthesis and subsequent aromatic hydrocarbon production, thereby improving overall production efficiency.
3Loss of substance
If by-products are not utilized, then the process is simpler, but significant amounts of material are lost, reducing overall efficiency
Solution Approach 1:
Instead of discarding by-products, the process recycles hydrogen-containing gas back to the synthesis gas production unit. This recovery approach converts what would be waste material into a valuable resource for maintaining optimal synthesis gas composition, reducing material loss and improving overall process efficiency.
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 significantly increases the yield of aromatic hydrocarbons by optimizing the conversion process, reducing by-product losses, and improving catalyst performance, thereby enhancing the overall efficiency of the production process.
Implementation Method 1
producing, from the methanol, in the presence of a catalyst, a concentrate of aromatic hydrocarbons and water
Implementation Method 2
in a second, high-temperature adiabatic reactor for synthesizing aromatic and aliphatic hydrocarbons from aliphatic hydrocarbons formed in the first reactor
Implementation Method 3
the subsequent stabilization of the concentrate of aromatic hydrocarbons in a stabilization unit
Implementation Method 4
using autothermal reforming technology with a pre-reforming unit or non-catalytic partial oxidation using oxygen or oxygen-air mixtures as the oxidant
Data Source
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AI summary
The invention relates to the field of gas chemistry and, more specifically, to methods and devices for producing aromatic hydrocarbons from natural gas, which involve producing synthesis gas, converting same into methanol, producing, from the methanol, in the presence of a catalyst, a concentrate of aromatic hydrocarbons and water, separating the water, air stripping hydrocarbon residues from the water, and separating-out the resultant concentrate of aromatic hydrocarbons and hydrogen-containing gas, the latter being at least partially used in the production of synthesis gas to adjust the ratio therein of H2:CO 1.8-2.3:1, and can be used for producing aromatic hydrocarbons. According to the invention, the production of aromatic hydrocarbons from methanol in the presence of a catalyst is carried out in two consecutively-connected reactors for synthesizing aromatic hydrocarbons: in a first, low-temperature isothermal reactor for synthesizing aromatic and aliphatic hydrocarbons, and in a second, high-temperature adiabatic reactor for synthesizing aromatic and aliphatic hydrocarbons from aliphatic hydrocarbons formed in the first reactor, and the subsequent stabilization thereof in an aromatic hydrocarbon concentrate stabilization unit. At least a portion of the hydrogen-containing gas is fed to a synthesis gas production unit and is used for producing synthesis gas using autothermal reforming technology. The installation carries out the method. The achieved technical result consists in increasing the efficiency of producing concentrates of aromatic hydrocarbons.