Hydrocarbon Reforming Product Recovery via Absorption and PSA
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Solution Overview
Problem
Catalytic reforming of hydrocarbons produces significant quantities of valuable hydrogen and lighter hydrocarbons, but existing methods do not effectively maximize the recovery of these products from the reforming reactor effluent, limiting the production of high octane gasoline and hydrogen.
Innovation Solution
The apparatus and method involve a separation zone to separate reforming-zone effluent into a net gas phase stream and a liquid phase hydrocarbon stream, followed by compression, partial condensation, and cooling, with an absorption zone to extract C3/C4 hydrocarbons and a pressure swing adsorption (PSA) zone to selectively separate hydrogen, enhancing the recovery of hydrogen and hydrocarbon products.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If conventional separation methods are used for reforming reactor effluent, then the process is simple, but the recovery of hydrogen and hydrocarbon products is insufficient
Solution Approach 1:
The separation system is divided into multiple functional zones: a separation zone for initial gas-liquid separation, an absorption zone for C3/C4 hydrocarbon extraction, and a PSA zone for hydrogen purification. Each zone performs a specific separation function, enabling comprehensive product recovery while maintaining manageable system complexity through modular design
Solution Approach 2:
An absorption medium is introduced as an intermediary substance to facilitate the extraction of C3/C4 hydrocarbons from the gas phase stream. This intermediary enables selective mass transfer of light hydrocarbons into the liquid phase, improving overall product recovery efficiency before the stream enters the PSA zone
2Quantity of substance
If lead-containing additives are used to improve octane numbers, then octane rating increases, but environmental pollution occurs
Solution Approach 1:
The process changes the chemical composition parameters of gasoline by producing high concentrations of aromatic hydrocarbons (benzene, toluene, xylenes) through catalytic reforming. These aromatics naturally provide high octane ratings without requiring lead additives, thereby eliminating the harmful environmental effects while maintaining the desired fuel quality parameter
Solution Approach 2:
The patent converts the challenge of removing lead additives into a benefit by maximizing the production and recovery of aromatic hydrocarbons through the separation and PSA processes. The aromatics, which would otherwise be lost or underutilized, are now recovered in high purity to replace lead as the octane-enhancing component
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 improves the recovery of hydrogen and hydrocarbon products, such as aromatic hydrocarbons, hydrogen-rich streams, and liquefied petroleum gas (LPG), thereby increasing the octane rating of gasoline and maximizing the yield of valuable reformate and hydrogen.
Implementation Method 1
The absorption zone comprises an absorber that is configured for contacting the cooled intermediate gas phase stream with the cooled liquid phase hydrocarbon stream to extract C3/C4 hydrocarbons from the cooled intermediate gas phase stream to the cooled liquid phase hydrocarbon stream
Implementation Method 2
The PSA zone contains an adsorbent for selectively separating H2 from hydrocarbons. The PSA zone is configured for receiving the H2-rich stream and for contacting the H2-rich stream with the adsorbent to form an H2-ultra rich stream
Implementation Method 3
A first cooler is configured to receive and partially condense and cool the compressed net gas phase stream to form a partially condensed, compressed net gas phase stream
Data Source
AI summary
Embodiments of apparatuses and methods for reforming of hydrocarbons including recovery of products are provided. In one example, a method comprises separating a reforming-zone effluent to form a net gas phase stream and a liquid phase hydrocarbon stream. The net gas phase stream is compressed, partially condensed and cooled, and separated to form an intermediate gas phase stream. The intermediate gas phase stream is cooled to form a cooled intermediate gas phase stream. The liquid phase hydrocarbon stream is cooled to form a cooled liquid phase hydrocarbon stream. The cooled intermediate gas phase stream is contacted with the cooled liquid phase hydrocarbon stream to form an H2-rich stream and a cooled second intermediate liquid phase hydrocarbon stream that is enriched with C3/C4 hydrocarbons. The H2-rich stream is contacted with an adsorbent to form an H2-ultra rich stream.