Millisecond Catalytic Wall Reactor for Autothermal Methane Conversion
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Solution Overview
Problem
Direct non-oxidative methane conversion (DNMC) technologies face challenges with high-temperature endothermic nature, low C2+ yields, and coke formation, requiring efficient reactor systems that are cost-effective and durable for methane conversion into value-added petrochemicals like ethylene and benzene.
Innovation Solution
A millisecond catalytic wall reactor with Fe/SiO2(Q) catalyst, where the catalyst is flame-fused to the reactor walls, enabling autothermal operation by coupling endothermic methane conversion with exothermic coke combustion, maintaining reaction stability and selectivity.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If high reaction temperatures exceeding 1200 K are used for DNMC on Fe/SiO2 catalyst, then methane conversion and C2+ yields are improved, but reactor design and operation become challenging due to heat supply requirements
Solution Approach 1:
The reactor is divided into two distinct zones: an endothermic reaction zone for methane conversion and an exothermic combustion zone for coke oxidation. This segmentation allows independent optimization of each zone's operating conditions and heat management, resolving the complexity of providing high heat supply for temperatures exceeding 1200 K while maintaining high methane conversion and C2+ yields.
Solution Approach 2:
The patent combines the endothermic methane conversion reaction and the exothermic coke combustion reaction into a single integrated reactor system. The heat generated from coke combustion in the exothermic zone is directly used to supply the high temperatures required for methane conversion in the endothermic zone, eliminating the need for external heat supply systems and simplifying reactor operation.
2Ease of manufacture
If fixed-bed reactor design is used for DNMC, then catalyst can be easily replaced, but heat supply for highly endothermic reaction becomes difficult to manage
Solution Approach 1:
The patent transitions from a traditional fixed-bed reactor configuration to a fluidized-bed reactor configuration. This dimensional change in the reactor system allows for superior heat transfer characteristics and uniform temperature distribution, making it easier to manage the highly endothermic reaction heat requirements while maintaining catalyst accessibility for replacement.
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
The solution achieves stable methane conversion, high C2+ selectivity, and long-term durability, optimizing lighter C2 or heavier aromatic product yields while reducing energy costs and reactor material costs, demonstrating technoeconomic viability for DNMC.
Implementation Method 1
The DNMC catalyst is a metal atom containing quartz that has the α-quartz crystalline phase, which is made by the hydrogen/oxygen (H2/O2) flame-fusion method.
Implementation Method 2
The reaction, however, is challenged by high-temperature endothermic nature
Implementation Method 3
coupling endothermic methane conversion with exothermic coke combustion
Implementation Method 4
The recently reported iron/silica (Fe/SiO2) catalyst is effective for DNMC
Data Source
AI summary
Disclosed herein are methane conversion devices that achieve autothermal conditions and related methods using the methane conversion devices.