Hydrocarbon Reforming Recovery Zone PSA Integration
Find Innovative SolutionsGenerate Solutions
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 other valuable hydrocarbons.
Innovation Solution
The implementation of a multi-zone process involving separation, pressure swing adsorption, and recontacting zones to selectively separate and enrich hydrogen and hydrocarbon streams, including the use of adsorbents to enhance hydrogen recovery and the extraction of C3/C4 hydrocarbons, resulting in a C5+ hydrocarbon-rich reformate and C3/C4 hydrocarbon-rich LPG streams.
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 lighter hydrocarbons is insufficient
Solution Approach 1:
The separation process is divided into multiple zones including a separation zone, first recovery zone, pressure swing adsorption zone, and second recontacting zone. Each zone performs a specific separation function, allowing progressive enrichment of hydrogen and lighter hydrocarbons while managing complexity through functional segmentation.
Solution Approach 2:
A liquid phase hydrocarbon stream is introduced as an intermediary medium in the first recovery zone and second recontacting zone to extract C3/C4 hydrocarbons from gas phase streams. This intermediary liquid stream enables efficient mass transfer and separation without requiring direct contact between all gas streams.
2Quantity of substance
If advanced multi-zone separation processes are implemented, then product recovery is maximized, but the device complexity increases
Solution Approach 1:
The liquid phase hydrocarbon stream serves multiple functions: it acts as an extractive medium in the first recovery zone, provides thermal mass for cooling in the second recontacting zone, and enables simultaneous extraction of C3/C4 hydrocarbons while condensing heavier components. This multi-functionality reduces the need for separate dedicated equipment for each function.
Solution Approach 2:
The process utilizes pressure swing adsorption to dynamically change pressure parameters, allowing the adsorbent material to selectively adsorb hydrogen at high pressure and release it at low pressure. This parameter change enables efficient hydrogen recovery without requiring complex continuous separation equipment.
3Manufacturing precision
If pressure swing adsorption is used for hydrogen separation, then hydrogen purity is enhanced, but the process requires additional equipment and operational complexity
Solution Approach 1:
Adsorbent materials with specific pore structures and surface properties are used in the pressure swing adsorption zone to selectively adsorb hydrogen molecules while allowing other gases to pass through. The porous structure provides high surface area for selective adsorption, achieving high hydrogen purity through material properties rather than complex mechanical separation.
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 process significantly improves the recovery of hydrogen and lighter hydrocarbons, enhancing the production of high octane gasoline and other valuable hydrocarbons by effectively separating and enriching the reforming-zone effluent streams, thereby maximizing product yield and quality.
Implementation Method 1
A pressure swing adsorption (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 and a PSA tail gas stream
Implementation Method 2
The PSA tail gas stream and at least a portion of the liquid phase hydrocarbon stream are combined and cooled to extract C3/C4 hydrocarbons from the PSA tail gas stream to the at least the portion of the liquid phase hydrocarbon stream for forming a H2, C2− hydrocarbons-containing gas stream and a cooled second intermediate liquid phase hydrocarbon 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 separated for forming an H2-rich stream and a first intermediate liquid phase hydrocarbon stream. The H2-rich stream is contacted with an adsorbent to form an H2-ultra rich stream and a pressure swing adsorption (PSA) tail gas stream. The PSA tail gas stream and at least a portion of the liquid phase hydrocarbon stream are combined and cooled to form a cooled two-phase combined stream. The cooled two-phase combined stream is separated into a H2, C2−hydrocarbons-containing gas stream and a cooled second intermediate liquid phase hydrocarbon stream.