Adsorbent and Membrane Separation for OCM Effluent
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Solution Overview
Problem
Conventional fractionation technologies in the refining and petrochemical industry are energy-intensive and costly, particularly in separating hydrocarbons like olefins from crude oil, and there is a need for non-cryogenic separation methods that can efficiently recover and purify hydrocarbons from streams such as oxidative coupling of methane (OCM) reactor effluents.
Innovation Solution
The use of adsorbents and membrane separation techniques, including pressure swing adsorption (PSA), membrane contactors, and metal-organic framework (MOF)-based separations, to selectively separate and enrich olefins like ethylene from hydrocarbon streams without requiring cryogenic conditions, thereby reducing energy consumption and operational costs.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If conventional fractionation technology is used to separate hydrocarbons, then separation of hydrocarbons can be achieved, but energy consumption and operational costs increase significantly
Solution Approach 1:
The patent changes the operating parameters from cryogenic temperatures to ambient or elevated temperatures, and from high-pressure distillation to atmospheric pressure adsorption. This parameter change enables the use of adsorbents like zeolites and activated carbon to separate olefins from paraffins without requiring the energy-intensive cryogenic distillation processes, thus resolving the contradiction between separation efficiency and energy consumption
Solution Approach 2:
The patent replaces the mechanical/thermal separation system (cryogenic distillation columns, heat exchangers, compressors) with a chemical/adsorptive separation system (adsorbent beds, pressure swing adsorption units). This substitution eliminates the need for complex thermal processing equipment and dramatically reduces energy requirements while maintaining effective separation of hydrocarbon components
2Manufacturing precision
If cryogenic distillation is used to separate hydrocarbons, then high purity products can be obtained, but the process becomes costly to install and operate
Solution Approach 1:
The patent employs inexpensive adsorbent materials such as zeolites, activated carbon, and other sorbents that can be easily manufactured and replaced. These adsorbents provide effective separation without requiring expensive cryogenic equipment, thereby reducing both installation costs and operational expenses while maintaining product purity through periodic regeneration or replacement of the adsorbent beds
3Productivity
If conventional separation methods are used for OCM effluent, then hydrocarbon recovery can be achieved, but the carbon footprint and energy requirements increase
Solution Approach 1:
The patent implements periodic action through pressure swing adsorption (PSA) cycles, where adsorbent beds are alternately pressurized for adsorption and depressurized for desorption/regeneration. This periodic operation enables continuous hydrocarbon recovery with lower energy requirements compared to continuous cryogenic distillation, as the adsorption process occurs at ambient temperatures and only requires periodic pressure changes rather than continuous thermal input
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
These methods enable efficient recovery and purification of hydrocarbons like ethylene, propylene, and methane, improving carbon efficiency and reducing the carbon footprint of OCM processes by minimizing energy requirements and eliminating the need for cryogenic distillation, thus making the separation process more cost-effective and environmentally friendly.
Implementation Method 1
utilizing techniques based the use of adsorbents
Implementation Method 2
pressure swing adsorption (PSA)
Implementation Method 3
membrane separation of CO2
Implementation Method 4
cryogenic or low temperature separation of CO2 having an operating temperature greater than a boiling point of methane and less than a boiling point of CO2
Implementation Method 5
metal-organic framework-based separation
Implementation Method 6
antisublimation separation of CO2
Data Source
AI summary
The present disclosure provides a method for generating higher hydrocarbon(s) from a stream comprising compounds with two or more carbon atoms (C2+), comprising introducing methane and an oxidant (e.g., O2) into an oxidative coupling of methane (OCM) reactor. The OCM reactor reacts the methane with the oxidant to generate a first product stream comprising the C2+ compounds. The first product stream can then be directed to a separations unit that recovers at least a portion of the C2+ compounds from the first product stream to yield a second product stream comprising the at least the portion of the C2+ compounds.