Carbon Monoxide Removal Zone for Hydrogen Stream Purification

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Solution Overview

Problem

In hydrocarbon reforming processes, the presence of carbon monoxide in the reduction zone leads to increased coking of catalysts, reducing their activity and selectivity, and necessitates operational adjustments that can result in product and profitability losses.

Innovation Solution

A process and apparatus that include a carbon monoxide removal zone to reduce carbon monoxide levels in the hydrogen stream from 5-100 vppm to no more than 10 vppm, using modified clinoptilolite adsorbents or methanation catalysts, which minimizes coking in the reforming reaction zone.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Ease of manufacture

If carbon monoxide is present in the reduction zone, then the catalyst reduction process can proceed, but higher coke forms on the catalyst in the reforming reactor

Engineering Contradiction:

Improvecatalyst reduction processVSAvoidcoke formation

Core Design Contradiction:

Ease of manufactureVSObject-generated harmful factors

Solution Approach 1:

The patent extracts and removes carbon monoxide from the hydrogen stream using a carbon monoxide removal zone positioned between the reduction zone and reforming reactor. This separation eliminates the harmful CO component while maintaining the beneficial hydrogen for catalyst reduction, preventing coke formation in the reforming reactor

Inventive Principle:

Principle #2Taking out (Extraction)

Solution Approach 2:

The patent introduces a carbon monoxide removal zone as an intermediary component between the reduction zone and reforming reactor. This intermediary zone contains adsorbents or catalysts that selectively remove CO from the hydrogen stream, acting as a mediator that protects the reforming reactor from coke formation while allowing the reduction process to proceed

Inventive Principle:

Principle #24Intermediary (Mediator)

2Productivity

If the hydrogen stream contains recycled hydrogen from reforming reactors operating at low pressures and high temperatures, then reformate yields are maximized, but carbon monoxide levels increase to 5-100 vppm

Engineering Contradiction:

Improvereformate yieldVSAvoidcarbon monoxide concentration

Core Design Contradiction:

ProductivityVSQuantity of substance

Solution Approach 1:

The patent applies preliminary action by removing carbon monoxide from the recycled hydrogen stream before it enters the reduction zone and reforming reactor. The carbon monoxide removal zone is positioned upstream to preemptively eliminate CO, preventing subsequent coke formation while maintaining the high reformate yields achieved through recycled hydrogen operation

Inventive Principle:

Principle #10Preliminary action

3Object-generated harmful factors

If feed rate is lowered to increase the hydrogen:hydrocarbon ratio, then coke formation is mitigated, but product and profitability losses occur

Engineering Contradiction:

Improvecoke formationVSAvoidproduct output

Core Design Contradiction:

Object-generated harmful factorsVSProductivity

Solution Approach 1:

The patent converts the harmful effect of carbon monoxide into a beneficial situation by removing CO from the hydrogen stream. This eliminates the root cause of coke formation, allowing the system to maintain high feed rates and productivity without suffering from coke-related catalyst deactivation, thereby avoiding product and profitability losses

Inventive Principle:

Principle #22Blessing in disguise (Convert harm into benefit)

4Reliability

If reforming reactor temperatures are increased to compensate for activity loss due to coking, then catalytic activity is maintained, but even higher coke levels are produced

Engineering Contradiction:

Improvecatalytic activityVSAvoidcoke level

Core Design Contradiction:

ReliabilityVSObject-generated harmful factors

Solution Approach 1:

The patent applies preliminary anti-action by removing carbon monoxide from the hydrogen stream before it contacts the catalyst in the reforming reactor. This preemptive removal prevents the initiation of coke formation reactions, eliminating the need to increase reactor temperatures to maintain catalytic activity, thereby avoiding the feedback loop that produces even higher coke levels

Inventive Principle:

Principle #9Preliminary anti-action

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 effectively reduces coking, maintaining catalytic activity and selectivity, and allows for improved operability by minimizing coke formation, thus enhancing process efficiency and profitability.

Implementation Method 1

using modified clinoptilolite adsorbents

Methodology Applied

Scientific EffectAdsorption: Adsorption

Implementation Method 2

using methanation catalysts

Methodology Applied

Scientific EffectCatalysis: Catalysis

Data Source

PatentUS7687049B2Apparatus and process for removal of carbon monoxide

Publication Date: 2010.03.30 UOP LLC

AI summary

One exemplary embodiment can be a process for lowering an amount of carbon monoxide in a stream rich in hydrogen. The process can include passing the stream rich in hydrogen through a carbon monoxide removal zone to produce a product stream having no more than about 10 vppm carbon monoxide and communicating the product stream to a reduction zone receiving a catalyst comprising unreduced metal species.