Hot Oxygen Generator Flexibility for Variable Partial Oxidation Feed
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Solution Overview
Problem
Existing hydrocarbon production plants face disruptions when there are changes in the characteristics of the feed material, requiring costly adjustments or shutdowns to maintain product quality and efficiency.
Innovation Solution
A method involving partial oxidation of hydrocarbon feedstock using a flexible hot oxygen generator system that allows for the use of alternate hydrocarbon streams and adjustments in oxygen stream conditions to maintain desired hydrogen-to-carbon monoxide ratios, even with changes in feedstock composition or availability.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If the plant operates with predetermined conditions based on assumed feed material characteristics, then the product quality can be maintained under stable conditions, but the plant cannot adapt when feed material characteristics change
Solution Approach 1:
The patent applies dynamics by making the operating conditions adjustable and flexible rather than fixed. The method allows continuous modification of reaction parameters (temperature, pressure, catalyst composition, feed rate) in response to changing feed material characteristics, enabling the system to adapt dynamically while maintaining product quality without requiring complex structural changes
Solution Approach 2:
The patent directly applies parameter changes by systematically adjusting key process parameters including temperature, pressure, catalyst properties, and feed rate when feed material characteristics change. This allows the plant to maintain optimal operation and product quality under varying feed conditions without discontinuing operations or installing costly substitute methodology
2Manufacturing precision
If the operator discontinues operations or installs costly substitute methodology to accommodate feed material changes, then product quality can be maintained, but productivity and operational efficiency decrease
Solution Approach 1:
The patent applies preliminary action by establishing a framework of adjustable parameters and control mechanisms in advance, so that when feed material changes occur, the operator can immediately adjust conditions rather than shutting down. The system is pre-configured to handle variations through flexible operating parameters, maintaining both product quality and continuous operation
Solution Approach 2:
The method enables dynamic adjustment of operating conditions to maintain product quality while ensuring operational continuity. By allowing real-time modification of temperature, pressure, catalyst, and feed rate parameters, the system avoids discontinuation of operations and costly substitute methodology while consistently producing quality products
3Productivity
If the plant is designed for specific feed material characteristics, then optimal product output can be achieved under designed conditions, but the plant becomes vulnerable to disruptions when conditions change
Solution Approach 1:
The patent applies parameter changes by establishing adjustable operating parameters that can be modified when feed material characteristics change from design specifications. This includes adjusting temperature, pressure, catalyst composition, and feed rate to maintain optimal productivity and operational stability under varying conditions, reducing vulnerability to disruptions
Solution Approach 2:
The method applies universality by designing the system to handle multiple feed material types and conditions through flexible parameter adjustment. The plant can accommodate variations in feed characteristics while maintaining optimal product output, making it less vulnerable to disruptions without requiring facility-specific redesign
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
Enables continuous production of hydrocarbon feedstock with consistent quality by decoupling the partial oxidation reactor from reliance on a single feed source, allowing for seamless adaptation to varying feed conditions without additional hardware or control changes.
Implementation Method 1
reacting the raw feed with the oxygen so that one or more of said light hydrocarbons in said raw feed is partially oxidized by said oxygen to increase the amounts of hydrogen and CO in the raw feed
Implementation Method 2
an oxygen stream that has a temperature of 1093 °C to 2593 °C (2000 °F to 4700 °F)
Data Source
Figure 1
Figure 2~3
AI summary
Disclosed are methods of using a hot oxygen generator to respond to changes in the characteristic of the feed to a partial oxidation reactor.