Microwave Plasma Hydrocarbon Processing for Continuous Carbon Removal
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Solution Overview
Problem
Current hydrocarbon liquefaction and upgrading processes are unable to operate continuously due to the buildup of carbon deposits within the system, requiring frequent shutdowns for maintenance and cleaning, which hampers commercial production efficiency.
Innovation Solution
A method involving the use of microwave energy to create plasmas in a reaction tube, where a cleaning gas, such as oxygen, is introduced to burn off carbon residue films without stopping the process, allowing for continuous operation by periodically delivering oxygen plasma to remove deposits and then vacuuming or flushing them out.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If conventional hydrocarbon liquefaction and upgrading processes are used, then fuel production can be achieved, but the system must be periodically shut down for vacuuming to remove carbon deposits
Solution Approach 1:
The patent introduces a cleaning gas (oxygen or air) into the reaction tube before carbon deposits accumulate to problematic levels. This preliminary action prevents heavy buildup by continuously or periodically removing carbon during the hydrocarbon processing operation, eliminating the need for complete system shutdowns for maintenance
Solution Approach 2:
The system maintains continuous operation by integrating the cleaning function into the ongoing hydrocarbon processing. The cleaning gas is introduced periodically or continuously during normal operation, allowing both hydrocarbon conversion and carbon removal to occur without interrupting the production process, thus achieving continuous useful action
2Reliability
If the system is shut down frequently for cleaning, then carbon deposits can be removed, but operational efficiency and commercial production capability are reduced
Solution Approach 1:
The system performs self-maintenance by using a cleaning gas introduced into the reaction tube to automatically remove carbon deposits during normal operation. This self-service cleaning mechanism eliminates the need for external intervention or complete system shutdowns, maintaining both system cleanliness and high productivity simultaneously
Solution Approach 2:
The cleaning gas is introduced periodically or continuously at controlled intervals during hydrocarbon processing. This periodic action maintains system cleanliness by preventing excessive carbon buildup while allowing the majority of the time to be dedicated to productive hydrocarbon conversion, thereby preserving commercial production 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 approach enables continuous processing of hydrocarbons by maintaining the microwave energy flow and using oxygen plasma to remove carbon deposits, reducing the need for frequent shutdowns and enhancing operational efficiency by minimizing disruptions.
Implementation Method 1
receiving microwaves in the waveguide from a microwave generator, propagating microwave energy from the waveguide into the reaction tube to cause the formation of a first plasma in the reaction tube
Implementation Method 2
propagating microwave energy from the waveguide into the reaction tube to cause the formation of a first plasma in the reaction tube, wherein the first plasma causes the feedstock and process gas to react
Implementation Method 3
forming a second plasma in the reaction tube, from the cleaning gas in the presence of the microwave energy, so that the second plasma causes burning off of a carbon residue film from the reaction tube
Implementation Method 4
forming a second plasma in the reaction tube, from the cleaning gas in the presence of the microwave energy
Data Source
AI summary
A method of processing hydrocarbons includes feeding a hydrocarbon feedstock into a reaction tube positioned within an opening of a waveguide, feeding a process gas into the reaction tube, receiving microwaves in the waveguide from a microwave generator, propagating microwave energy from the waveguide into the reaction tube to cause the formation of a first plasma in the reaction tube, that causes the feedstock and process gas to react and form into a product stream comprising a fuel product. The method also includes periodically, without stopping the propagation of microwave energy into the reaction tube, delivering a cleaning gas comprising oxygen. The method may also include forming a second plasma in the reaction tube, from the cleaning gas that causes burning off of a carbon residue film from the reaction tube; extracting the cleaning gas from the product stream; and delivering the extracted cleaning gas to the cleaning gas source.