Oxygen Storage Reactor for C5+ Hydrocarbon Production
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Current processes for converting methane to higher molecular weight hydrocarbons, such as aromatics, face challenges including low methane conversion efficiency, high energy intensity, and undesired combustion reactions, which limit the production of C5+ hydrocarbons and increase environmental impact.
Innovation Solution
A hydrocarbon conversion process utilizing a flow-through reactor with a combination of oxidative coupling, oxydehydrogenation, and dehydrocyclization catalysts, along with an oxygen storage material, where oxygen is stored and released to control reactions, reducing combustion and enhancing selectivity for C5+ products like aromatics.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If oxidative coupling methods are used to convert methane to higher hydrocarbons, then C5+ hydrocarbon production is achieved, but undesired combustion reactions occur and energy efficiency decreases
Solution Approach 1:
The catalyst system is segmented into distinct functional components: a first catalyst for oxidative coupling/oxydehydrogenation and a second catalyst for dehydrocyclization. This segmentation allows each catalyst to perform its specific function optimally, preventing undesired combustion reactions while maintaining high C5+ hydrocarbon production efficiency
Solution Approach 2:
An oxygen storage material acts as an intermediary between the oxidant and the hydrocarbon conversion reactions. It stores oxygen during an oxygen storage phase and releases it during a hydrocarbon conversion phase, enabling precise control of oxygen availability to prevent combustion while facilitating the desired reactions
2Productivity
If conventional oxidative coupling processes are used, then methane conversion occurs, but selectivity for desired products decreases due to combustion reactions
Solution Approach 1:
The oxygen storage material undergoes preliminary oxygen storage before the hydrocarbon conversion phase. This preliminary action ensures that oxygen is available in controlled amounts during the conversion phase, enabling high methane conversion while maintaining product selectivity by preventing premature combustion
Solution Approach 2:
The process operates in periodic cycles alternating between an oxygen storage phase and a hydrocarbon conversion phase. This periodic action allows the system to accumulate oxygen when not converting hydrocarbons, then release it in controlled amounts during conversion, thereby achieving both high conversion and selectivity
3Productivity
If oxygen is continuously supplied to enhance reaction rate, then productivity increases, but undesired combustion reactions increase
Solution Approach 1:
The oxygen storage material serves as an intermediary that decouples oxidant supply from the hydrocarbon conversion reaction. It absorbs oxygen during non-conversion periods and releases it during conversion periods, enabling high reaction rates without continuous oxygen supply that would cause combustion
Solution Approach 2:
The process dynamically changes the oxygen availability parameter by switching between oxygen storage and release modes. During hydrocarbon conversion, oxygen is released in controlled amounts to maintain high reaction rates while preventing the excess oxygen that would lead to combustion reactions
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 process achieves higher selectivity and energy efficiency for producing C5+ hydrocarbons, particularly aromatics, by regulating oxygen storage and flow, thereby minimizing undesired combustion reactions and increasing methane conversion.
Implementation Method 1
an oxygen storage material, where oxygen is stored and released to control reactions
Implementation Method 2
at least a portion of the released oxygen reacts with at least a portion of the hydrocarbon reactant in the presence of the first hydrocarbon conversion catalyst to produce a first reaction mixture comprising a C2+ composition
Implementation Method 3
at least a portion of the first reaction mixture's C2+ hydrocarbon is catalytically converted in the presence of the second hydrocarbon conversion catalyst to produce a second reaction mixture comprising a C5+ hydrocarbon composition
Data Source
AI summary
Disclosed are reactors and reaction processes for contacting hydrocarbon reactant in the presence of oxygen stored and released within a thermal mass region of the reactor, and catalytically converting at least a portion of alkane, e.g., methane, in the hydrocarbon reactant to produce a reaction mixture comprising a C5+ composition. Oxygen storage and release for carrying out the catalytic conversion is achieved by including an oxygen storage material in a thermal mass region of the reactor. Flow-through reactors can be used to carry out oxygen storage and the hydrocarbon conversion reactions. Reverse-flow reactors are examples of flow-through reactors, which can be used to carry out oxygen storage and the hydrocarbon conversion reactions.