CO2 Removal Membrane Process With Integrated Cooling Recovery
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Solution Overview
Problem
Current carbon dioxide removal processes from hydrocarbon streams face challenges in minimizing hydrocarbon losses and achieving efficient recovery at high pressure, leading to increased separation costs and energy inefficiencies.
Innovation Solution
A process combining a membrane separation unit with a heat exchanger and a carbon dioxide separation unit, where the streams from the carbon dioxide separation unit provide cooling and fuel for compressors, optimizing energy recovery and reducing hydrocarbon losses.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If traditional two-stage membrane processes are used to remove carbon dioxide from hydrocarbon streams, then carbon dioxide separation efficiency is improved, but hydrocarbon losses increase and operating costs increase
Solution Approach 1:
The patent changes the operating parameters by integrating a heat exchanger that recovers cooling energy from the carbon dioxide separation unit and uses it to cool the feed stream to the membrane separation unit. This parameter change (using recovered cooling instead of external cooling) reduces energy waste and minimizes hydrocarbon losses while maintaining high carbon dioxide separation efficiency
Solution Approach 2:
The system performs self-service by using the cold carbon dioxide-rich stream from the separation unit to cool the incoming hydrocarbon feed stream through the heat exchanger. This self-cooling mechanism eliminates the need for external cooling systems and reduces hydrocarbon condensation losses, thereby addressing both separation efficiency and hydrocarbon loss concerns
2Quantity of substance
If membrane separation is used to remove carbon dioxide, then carbon dioxide enrichment is achieved, but energy efficiency deteriorates due to lack of heat recovery
Solution Approach 1:
The patent implements a feedback loop where the cold stream exiting the carbon dioxide separation unit is redirected through the heat exchanger to cool the incoming feed. This feedback mechanism recovers the cooling energy that would otherwise be wasted, significantly improving energy efficiency while maintaining carbon dioxide enrichment levels
Solution Approach 2:
The heat exchanger utilizes phase transition or temperature differential between the cold carbon dioxide-rich stream and the warmer hydrocarbon feed stream to transfer cooling energy. This thermal energy recovery through temperature differential eliminates energy waste and improves overall process energy efficiency
3Reliability
If high pressure carbon dioxide recovery is implemented, then carbon dioxide utilization value is improved, but capital costs and operating costs increase
Solution Approach 1:
The patent merges the cooling function into the existing carbon dioxide separation process by integrating a heat exchanger that uses the cold separation outlet stream to cool the feed. This combination eliminates the need for separate cooling systems and reduces both capital costs and operating costs while maintaining high pressure carbon dioxide recovery for utilization
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 minimizes hydrocarbon losses, enables cost-effective recovery of high-pressure carbon dioxide, and lowers capital and operating costs compared to traditional two-stage membrane processes.
Implementation Method 1
Membranes have been used to remove carbon dioxide and other acid/polar gases from natural gas. Membrane processes have been used to serve as a bulk cut separation of carbon dioxide. In such processes the carbon dioxide permeates through the membrane thereby giving rise to a carbon dioxide enriched permeate gas
Implementation Method 2
a heat exchanger and a carbon dioxide separation unit wherein the streams obtained in the carbon dioxide separation unit are utilized to provide the cooling effect in the heat exchanger
Implementation Method 3
separating and purifying the compressed, cooled first membrane stream in a carbon dioxide separation unit to produce a carbon dioxide rich liquid stream and a carbon dioxide lean vapor stream
Data Source
AI summary
A process for efficiently removing carbon dioxide from a hydrocarbon containing feed stream utilizing a membrane separation unit in conjunction with a heat exchanger and a carbon dioxide separation unit wherein the streams obtained in the carbon dioxide separation unit are utilized to provide the cooling effect in the heat exchanger.