Dual-Stage Methane Conversion Reactor for Syngas Optimization
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Solution Overview
Problem
Current methane conversion reactors face issues such as high oxygen consumption, high power and capital costs, sooting, low thermodynamic efficiency, and difficulties in adjusting the H2/CO ratio, leading to reduced catalyst activity and increased impurity gases in the product.
Innovation Solution
The apparatus features a reactor design with an upper and lower casing, a coaxial mixer, and catalyst sublayers, where a vapor-methane mixture is supplied to the tubular annulus and a vapor-air mixture to the center tube, with methane combustion occurring over the upper catalyst sublayer, followed by additional conversion in the lower sublayer using sensible heat, optimizing the H2/CO ratio and reducing impurity gases.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Quantity of substance
If partial oxidation of natural gas is performed with oxygen to obtain syngas, then H2 and CO are produced, but oxygen consumption exceeds the weight of converted natural gas requiring high power consumption
Solution Approach 1:
The invention changes the oxygen supply parameters by introducing oxygen-containing gas at multiple stages with controlled concentrations (first stage: 2-10% O2, second stage: 5-15% O2), rather than using pure oxygen or excessive air, thereby reducing overall oxygen consumption and associated power costs
Solution Approach 2:
The oxidation process is segmented into two distinct stages: first stage oxidation in the presence of catalyst sublayers, and second stage oxidation after catalyst removal. This segmentation allows optimized oxygen dosing at each stage, preventing excessive oxygen consumption and reducing power consumption for oxygen production and compression
2Productivity
If intermediate stages and side reactions are present in methane conversion, then the process can proceed through multiple steps, but content of target components in product gas is significantly reduced
Solution Approach 1:
The catalyst is removed between the first and second oxidation stages. This extraction of the catalyst after the first stage prevents it from catalyzing unwanted side reactions in the second stage, thereby increasing target component content while maintaining a relatively simple two-stage process structure
Solution Approach 2:
The system dynamically adjusts the oxidation conditions by changing catalyst presence (present in stage 1, removed in stage 2) and oxygen concentration (2-10% then 5-15%). This dynamic control optimizes the balance between conversion efficiency and target component content without requiring excessive process stages
3Quantity of substance
If air compression is used in the methane conversion process, then oxygen is supplied to the reactor, but thermodynamic efficiency is reduced due to compression expenditures
Solution Approach 1:
The invention uses oxygen-containing gas with controlled oxygen concentration (2-10% in first stage, 5-15% in second stage) instead of compressing pure oxygen or using excessive air. This parameter optimization reduces the work required for gas compression while ensuring adequate oxygen supply, thereby improving thermodynamic efficiency
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 design enhances the efficiency of lower paraffin hydrocarbons conversion, increases the H2/CO ratio, decreases capital and metal consumption, and reduces impurity gases like nitrogen and argon, while maintaining process efficiency and product quality.
Implementation Method 1
converting the mixture in the presence of a monolithic catalyst
Implementation Method 2
partial oxidation of natural gas with oxygen
Implementation Method 3
combustion chamber for methane or natural gas with air oxygen
Implementation Method 4
Heat exchanger for cooling oxidation products and heating the air supplied to combustion chamber
Implementation Method 5
layer of reforming catalyst located inside it
Data Source
Figure 1
AI summary
This invention relates to an apparatus and a method for obtaining hydrogen, hydrogen-methane mixture, reaction gas containing H2 for producing hydrogen, alcohols, ammonia, dimethyl ether, ethylene, for Fischer-Tropsch processes and may be used in gas and gas-chemical industry for the processing of hydrocarbon gases and also in technologies involving the application of hydrogen-methane mixture. According to this invention, the apparatus for obtaining hydrogen-bearing gas comprises a pressurized reactor casing; devices for supply of vapor-methane mixture and vapor-air mixture and for output of product gas; refractory lining on inner wall of the casing and a layer of methane conversion catalyst located inside it and also comprising upper and lower sublayers. Methane is supplied between catalyst sublayers. The reactor casing is made of parts of various diameters, so that upper catalyst sublayer is placed in a larger diameter part of casing and lower catalyst sublayer is placed in a lower part with smaller diameter. 2 independent claims, fig.