Hydration Separation Unit for Hydrogen Concentration
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Solution Overview
Problem
Conventional methods for increasing hydrogen concentration in hydrogenation reactors are inefficient, leading to high equipment costs and energy consumption, as they either require hydrogen purge or are not suitable for high-pressure hydrocracking units.
Innovation Solution
The introduction of a hydration separation unit with a hydration reactor and hydrate decomposer, utilizing a water-in-oil microemulsion to form hydrates with light hydrocarbon components, effectively increasing hydrogen concentration by removing these components from the gas mixture, thereby reducing the total reacting pressure and enhancing hydrogen partial pressure.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Quantity of substance
If conventional high-pressure separation is used to maintain hydrogen concentration, then hydrogen purity can be maintained at about 85%, but hydrogen purge is required and equipment investment remains high
Solution Approach 1:
The invention changes the physical-chemical parameters of the system by introducing a hydrate formation process at high pressure (10-50 MPa) and low temperature (268-273 K), transforming the separation mechanism from conventional high-pressure mechanical separation to hydrate-based selective absorption, thereby achieving higher hydrogen concentration without proportionally increasing equipment pressure ratings
Solution Approach 2:
The invention introduces water as an intermediary substance that forms hydrates with light hydrocarbon components (methane, ethane) in the recycle gas stream. This intermediary enables selective removal of impurities through hydrate formation and subsequent separation, achieving hydrogen concentration enhancement without requiring extreme pressure equipment
2Quantity of substance
If membrane separation technology is used to separate high-pressure gases, then hydrogen concentration can be increased, but the obtained hydrogen pressure is too low requiring huge pressurization and high energy consumption
Solution Approach 1:
The invention utilizes the phase transition phenomenon of hydrate formation and decomposition. By controlling temperature and pressure conditions, light hydrocarbons transition from gas phase to hydrate solid phase for separation, then decompose back to gas phase at lower pressure. This phase transition mechanism enables concentration enhancement without the energy-intensive pressurization required by membrane technology
Solution Approach 2:
The invention employs periodic operation cycles alternating between hydrate formation (at high pressure, low temperature) and hydrate decomposition (at low pressure, higher temperature). This periodic action allows continuous hydrogen concentration enhancement while managing energy input efficiently, avoiding the continuous high-energy pressurization needed in membrane systems
3Quantity of substance
If hydrogen concentration in recycle stream is increased to over 95%, then hydrogen purge can be avoided and equipment pressure can be reduced, but conventional methods cannot achieve this concentration level
Solution Approach 1:
The invention replaces conventional mechanical separation systems (high-pressure separators, compressors) with a chemical-physical separation mechanism based on hydrate formation. This substitution enables achieving over 95% hydrogen concentration through selective hydrate formation with impurities rather than relying on mechanical pressure differentials, making the method applicable to existing hydrocracking units
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 increases hydrogen concentration to over 95%, reducing equipment investment, lowering energy consumption, and improving the yield and transformation efficiency of light oils, while maintaining high hydrogen partial pressure.
Implementation Method 1
a hydration reactor (1) into which a water-in-oil microemulsion is introduced whereby the light hydrocarbon components (methane, ethane, etc.) of the gas mixture from the high pressure separator are combined into the water-in-oil microemulsion by forming hydrates
Data Source
AI summary
An apparatus and a method that increase the concentration of recycled hydrogen in the hydrogenation unit are disclosed having a hydration separation unit included between the high-pressure separator and hydrocracking reactor. A part of the recycled hydrogen contacts with the water-in-oil microemulsion to form hydrates from which the light hydrocarbon components are removed. The gas flow entering into the hydration separation unit is present in amount of 20%˜100% of the total gas flow coming from the high-pressure separator; the water-in-oil microemulsion, in which the volume ratio of oil and water is 1:1 to 5:1 may increase hydrogen partial pressure in the reactor and thus upgrade the performance of hydrogenation.