Method and apparatus for producing hydrocarbons

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Solution Overview

Problem

Current methods for oxidative coupling of methane suffer from low yields and high methane recycling losses, requiring significant purification efforts to prevent impurities from entering the reactor, and lack efficient separation of hydrocarbons with two or more carbon atoms.

Innovation Solution

A method where a liquid, methane-rich stream is externally formed and used as makeup, rather than recycled from the product stream, allowing for cryogenic treatment and minimizing ethylene loss by using pressurized natural gas to provide a methane-rich stream for the reaction unit and separation processes, thereby reducing the need for additional purification and maintaining a standardized methane supply.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Productivity

If methane-rich stream is recycled from product stream, then methane utilization is improved, but purification effort increases and ethylene loss occurs

Engineering Contradiction:

Improvemethane utilizationVSAvoidpurification effort

Core Design Contradiction:

ProductivityVSDevice complexity

Solution Approach 1:

The invention applies preliminary action by forming the liquid methane-rich stream externally before it enters the reaction system. This external formation allows the stream to be prepared in advance with controlled composition and purity, avoiding the need for complex purification of recycled streams and preventing ethylene loss that would occur during recycling purification processes.

Inventive Principle:

Principle #10Preliminary action

2Manufacturing precision

If liquid methane-rich stream is used for cryogenic treatment, then hydrocarbon separation is improved, but methane supply complexity increases

Engineering Contradiction:

Improvehydrocarbon separationVSAvoidmethane supply system

Core Design Contradiction:

Manufacturing precisionVSDevice complexity

Solution Approach 1:

The invention uses an intermediary approach by introducing an externally formed liquid methane-rich stream as a mediator between the natural gas source and the reaction system. This intermediary stream serves dual purposes: it provides the necessary liquid refrigerant for cryogenic separation and simultaneously supplies methane to the reaction system, simplifying the overall supply architecture while maintaining high separation precision.

Inventive Principle:

Principle #24Intermediary (Mediator)

3Object-affected harmful factors

If fresh methane is fed to reactor, then impurity introduction is reduced, but purification requirements increase

Engineering Contradiction:

Improveimpurity introductionVSAvoidpurification requirement

Core Design Contradiction:

Object-affected harmful factorsVSEase of manufacture

Solution Approach 1:

The invention applies parameter changes by transforming methane from gaseous state in natural gas to liquid state in the methane-rich stream. This phase change enables the methane to be introduced in a form that is inherently free from typical gaseous impurities, while the liquid state facilitates easier handling and dosing, reducing both impurity introduction and purification requirements.

Inventive Principle:

Principle #35Parameter changes

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 enhances methane recycling efficiency, reduces ethylene loss, and simplifies purification by using fresh, externally provided liquid methane, allowing for independent operation of reaction and separation units with improved hydrocarbon separation and reduced impurity introduction.

Implementation Method 1

a product stream containing hydrocarbons is produced from a methane-rich feed stream and from an oxygen-rich feed stream in a reaction unit configured for implementing a method for oxidative coupling of methane, the product stream or at least a stream formed from the product stream being treated cryogenically in at least one separation unit with the aid of at least one liquid, methane-rich stream

Methodology Applied

Scientific EffectHeat exchange: Heat Exchanger

Implementation Method 2

at least one liquid, methane-rich stream is used as refrigerant in a heat exchanger and/or as reflux in a distillation column and/or as absorbing solution in an absorption column

Methodology Applied

Scientific EffectCryogenic cooling: Cryogenics

Implementation Method 3

Methodology Applied

Scientific EffectAbsorption: Absorption (physical)

Data Source

PatentUS10329214B2Method and apparatus for producing hydrocarbons

Publication Date: 2019.06.25 LINDE AG

AI summary

A method for producing hydrocarbons is proposed, in which a product stream containing hydrocarbons is produced from a methane-rich feed stream and from an oxygen-rich feed stream in a reaction unit which is configured for implementing a method for oxidative coupling of methane, the product stream or at least a stream formed therefrom being treated cryogenically in at least one separation unit using at least one liquid, methane-rich stream. It is provided that in the at least one separation unit (10) a recycle stream is formed from methane contained in product stream (c) and from methane contained in the at least one liquid, methane-rich stream (e, v), the recycle stream being fed to the reaction unit (1) as the methane-rich feed stream (a), and in that the liquid, methane-rich stream (e, v) is provided as makeup.