Natural Gas Refining Assembly Using Catalytic Methane Conversion
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Solution Overview
Problem
Rich natural gas requires efficient purification to separate methane from heavier hydrocarbons, with existing methods often inefficient in achieving high methane concentration and utilizing costly processes.
Innovation Solution
A refining assembly and method that includes a methane-producing assembly with a catalyst, vaporizer, and purification assembly to convert heavier hydrocarbons with water into methane, hydrogen, and carbon oxide gases, while allowing methane to pass unconverted, followed by water and gas removal to enhance methane concentration.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If existing purification methods are used to separate methane from heavier hydrocarbons, then separation is achieved, but the process is costly and inefficient in achieving high methane concentration
Solution Approach 1:
The patent changes the chemical parameters of the system by introducing a catalyst and controlling temperature and pressure conditions to convert heavier hydrocarbons into methane through chemical reaction, rather than relying on physical separation methods. This transforms the purification approach from separation-based to conversion-based, achieving higher methane concentration at lower cost
Solution Approach 2:
The patent introduces a catalyst as an intermediary substance that facilitates the conversion of heavier hydrocarbons to methane. The catalyst enables the chemical transformation without being consumed in the reaction, allowing efficient conversion while maintaining process economy
2Manufacturing precision
If heavier hydrocarbons are converted to methane through chemical reaction, then methane concentration increases, but additional processing steps and catalysts are required
Solution Approach 1:
The patent combines the purification function with the methane production function into a single integrated process. The chemical conversion step simultaneously removes heavier hydrocarbons and generates additional methane, merging separation and production operations into one step, thereby reducing overall process complexity despite introducing catalytic conversion
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 effectively increases methane concentration, reduces water and impurities, and utilizes cost-effective processes for producing a high-quality methane-rich stream suitable for various applications.
Implementation Method 1
a methane-producing assembly with a catalyst to convert heavier hydrocarbons with water into methane
Implementation Method 2
converting at least a substantial portion of the other hydrocarbons with the water to a second methane gas, a lesser portion of the water, hydrogen gas, and carbon oxide gas
Implementation Method 3
a vaporizer configured to receive and vaporize at least a portion of at least one liquid-containing feed stream that includes water and rich natural gas to form an at least substantially vaporized stream
Implementation Method 4
a first heating assembly configured to receive at least one fuel stream and at least one air stream and produce a heated exhaust stream for heating at least one of the vaporizer to at least a minimum vaporization temperature or the methane-producing reactor to at least a minimum methane-producing temperature
Data Source
AI summary
Refining assemblies and methods for refining rich natural gas containing a first methane gas and other hydrocarbons that are heavier than methane gas are disclosed. In some embodiments, the assemblies may include a methane-producing assembly configured to receive at least one liquid-containing feed stream that includes water and rich natural gas and to produce an output stream therefrom by (a) converting at least a substantial portion of the other hydrocarbons of the rich natural gas with the water to a second methane gas, a lesser portion of the water, and other gases, and (b) allowing at least a substantial portion of the first methane gas from the rich natural gas to pass through the methane-producing assembly unconverted. The assemblies may additionally include a purification assembly configured to receive the output stream and to produce a methane-rich stream therefrom having a greater methane concentration than the output stream.