Hydrate Formation Reactor for Methane Separation
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Solution Overview
Problem
Current methods for separating methane from gas mixtures containing ethane and other hydrocarbons are costly and energy-intensive, particularly in cryogenic distillation, and do not efficiently address the removal of corrosive gases like H2S and CO2.
Innovation Solution
A hydrate-based separation system using a hydrate formation reactor with countercurrent flow of a gas stream and an aqueous phase, where C2 or C2+ gases are captured into a hydrate structure, allowing for the selective removal of these gases from natural gas streams, with optional use of hydrate promoters to optimize conditions.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If cryogenic distillation is used to separate methane from C2-C5 hydrocarbons, then separation effectiveness is improved, but energy consumption and cost increase significantly
Solution Approach 1:
The patent utilizes hydrate formation as a phase transition mechanism to separate C2-C5 hydrocarbons from methane. By controlling temperature and pressure conditions, the system induces hydrate formation selectively for C2-C5 components, achieving separation without the high energy consumption of cryogenic distillation. The hydrate phase acts as a selective carrier for heavier hydrocarbons.
Solution Approach 2:
The invention changes the operating parameters from extreme cryogenic temperatures to milder conditions where hydrate formation occurs. By adjusting temperature and pressure to specific ranges that favor hydrate stability, the system achieves effective separation at lower energy input compared to traditional distillation methods.
2Manufacturing precision
If conventional separation methods are used, then C2-C5 hydrocarbons can be removed, but the process becomes costly and energy intensive
Solution Approach 1:
The patent introduces an aqueous phase as an intermediary medium that facilitates hydrate formation. This aqueous phase acts as a mediator between the gas stream and the hydrate structure, enabling selective capture of C2-C5 hydrocarbons. The intermediary phase lowers the energy barrier for hydrate formation and improves separation efficiency.
3Device complexity
If single-unit separation is implemented, then device complexity is reduced, but the ability to separate multiple components (methane, C2-C5, H2S, CO2) simultaneously is limited
Solution Approach 1:
The hydrate-based separation system performs multiple separation functions within a single unit. It can simultaneously separate C2-C5 hydrocarbons, H2S, and CO2 from methane by exploiting the different hydrate formation characteristics of each component. This multi-functionality eliminates the need for multiple separate separation units while maintaining comprehensive separation capability.
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 significantly reduces energy and cost while effectively separating methane from C2 or C2+ gases and corrosive components, enabling efficient purification and utilization of methane and C2-rich products for industrial processes.
Implementation Method 1
C2 or C2+ gas is preferentially captured into a hydrate structure to selectively remove C2 or C2+ gas from a gas stream
Implementation Method 2
a feed gas stream comprising methane and C2 or C2+ gas and an aqueous phase stream are contacted in the reactor in a countercurrent flow
Data Source
AI summary
Processes for separating methane from a gas mixture that comprises methane and C2 gas, including C2+ gas, and other gases, including CO2 and H2S, that are based upon formation of gas hydrates, and systems useful for implementing such processes, are disclosed.