Methane-Producing Assembly for Rich Natural Gas Refining
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Solution Overview
Problem
Rich natural gas, which contains methane and heavier hydrocarbons, requires purification to separate methane from other hydrocarbons for various applications, but existing methods are inefficient in achieving high methane concentration and effective utilization of byproducts.
Innovation Solution
A refining assembly and method that includes a methane-producing assembly with a catalyst to convert heavier hydrocarbons with water into methane, hydrogen, and carbon oxide gases, while allowing methane to pass through unconverted, followed by a purification assembly to enhance methane concentration and separate byproducts.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If conventional separation methods are used to purify rich natural gas, then some methane can be separated from heavier hydrocarbons, but the methane concentration in the output stream is insufficient and the process is inefficient
Solution Approach 1:
The patent changes the chemical state parameters of the system by introducing water and applying heat to convert heavier hydrocarbons into methane through chemical reactions. This transforms the purification process from simple physical separation to chemical conversion, achieving both high methane concentration and efficient utilization of heavier hydrocarbons
Solution Approach 2:
The patent converts the harmful or unwanted heavier hydrocarbons that need to be removed into beneficial methane gas through chemical conversion processes. Instead of merely separating and discarding these components, they are transformed into useful product, improving both purification efficiency and resource utilization
2Manufacturing precision
If heavier hydrocarbons are completely converted to methane, then methane concentration increases, but all hydrocarbon compounds are consumed and cannot be utilized in other applications
Solution Approach 1:
The patent applies partial conversion action by allowing some heavier hydrocarbons to pass through the conversion process unchanged. This enables simultaneous production of methane from converted hydrocarbons and preservation of unconverted hydrocarbons for other applications, optimizing both methane concentration and resource availability
Solution Approach 2:
The patent segments the hydrocarbon stream into different pathways: one for conversion to methane and another for direct utilization. This segmentation allows different portions of the hydrocarbon mixture to be processed differently, maximizing overall value and utility of all components
3Manufacturing precision
If complex purification processes are used to achieve high methane concentration, then product quality improves, but device complexity and operational difficulty increase
Solution Approach 1:
The patent merges multiple functions into a single integrated assembly: vaporization of water, chemical conversion of heavier hydrocarbons to methane, and separation/purification of the output stream. This consolidation achieves high methane concentration while reducing overall system complexity compared to multiple separate units
Solution Approach 2:
The purification assembly is designed with multi-functionality, handling vaporization, chemical conversion, and separation tasks within a single system. This universal design simplifies operation and reduces the number of components needed while maintaining high product quality
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
The solution effectively increases methane concentration in the output stream, enabling its use in combustion engines and other applications while utilizing the separated hydrocarbons in petrochemical processes, space heating, and fuel blending.
Implementation Method 1
a methane-producing assembly with a catalyst to convert heavier hydrocarbons with water into methane
Implementation Method 2
converting at least a substantial portion of the other hydrocarbons with the water to a second methane gas, a lesser portion of the water, hydrogen gas, and carbon oxide gas
Implementation Method 3
a vaporizer configured to receive and vaporize at least a portion of at least one liquid-containing feedstream that includes water and rich natural gas to form an at least substantially vaporized stream
Implementation Method 4
a first heating assembly configured to receive at least one fuel stream and at least one air stream and produce a heated exhaust stream for heating at least one of the vaporizer to at least a minimum vaporization temperature or the methane-producing reactor to at least a minimum methane-producing temperature
Implementation Method 5
a purification assembly configured to receive the output stream and to produce a methane-rich stream therefrom having a greater methane concentration than the output stream
Data Source
AI summary
Refining assemblies and methods for refining rich natural gas containing a first methane gas and other hydrocarbons that are heavier than methane gas are disclosed. In some embodiments, the assemblies may include a methane-producing assembly configured to receive at least one liquid-containing feed stream that includes water and rich natural gas and to produce an output stream therefrom by (a) converting at least a substantial portion of the other hydrocarbons of the rich natural gas with the water to a second methane gas, a lesser portion of the water, and other gases, and (b) allowing at least a substantial portion of the first methane gas from the rich natural gas to pass through the methane-producing assembly unconverted. The assemblies may additionally include a purification assembly configured to receive the output stream and to produce a methane-rich stream therefrom having a greater methane concentration than the output stream.