Reverse-Flow Pyrolysis Reactor for Hydrocarbon Conversion
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Solution Overview
Problem
The conventional process for converting hydrocarbons to unsaturated products faces inefficiencies due to thermal imbalances and the need for additional oxidation steps, leading to reduced conversion rates and increased energy consumption.
Innovation Solution
A regenerative, reverse-flow pyrolysis reactor system with multiple channels and controlled reactant flow intervals, where fuel and oxidant react exothermically to heat the reactor and combust combustible non-volatiles, optimizing thermal efficiency and product yield.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If conventional four-step process with separate reactor pairs is used, then hydrocarbon conversion to unsaturated products is achieved, but thermal imbalances occur and additional oxidation steps are required leading to reduced efficiency
Solution Approach 1:
The patent combines the pyrolysis and oxidation functions into a single reactor system with multiple channels. The first channel performs pyrolysis of hydrocarbons to produce unsaturated products, while the second channel simultaneously performs oxidation of coke deposits. This merging eliminates thermal imbalances between separate reactor pairs and removes the need for additional oxidation steps, directly improving conversion efficiency and reducing energy loss.
Solution Approach 2:
The reactor system operates with periodic switching between different operational modes. During operation, the system alternates between pyrolysis mode (converting hydrocarbons to unsaturated products) and oxidation mode (combusting coke deposits). This periodic action allows the same reactor to perform multiple functions sequentially, resolving the thermal imbalance issue that plagues conventional continuous four-step processes with separate reactor pairs.
2Productivity
If multiple separate reactors are used for pyrolysis and oxidation, then complete conversion is achieved, but device complexity increases
Solution Approach 1:
The patent designs a single reactor system that performs multiple functions: pyrolysis of hydrocarbons in the first channel, oxidation of coke deposits in the second channel, and heat transfer between channels. This multi-functional reactor eliminates the need for separate dedicated pyrolysis reactors and oxidation reactors, reducing device complexity while maintaining complete conversion through the coordinated operation of its multiple channels.
Solution Approach 2:
The reactor is segmented into multiple independent channels within a single reactor body. The first channel is dedicated to pyrolysis reactions, while the second channel handles oxidation. This segmentation allows each channel to be optimized for its specific function while sharing common reactor infrastructure (heating system, control mechanisms), thereby achieving complete conversion without the full complexity of multiple separate reactors.
3Object-generated harmful factors
If conventional oxidation steps are performed separately, then coke removal is achieved, but process time increases
Solution Approach 1:
The patent merges the coke removal oxidation step with the pyrolysis operation by providing a second channel within the same reactor. While the first channel continues pyrolysis, the second channel simultaneously performs oxidation of coke deposits. This parallel operation within a single reactor eliminates the need for separate sequential oxidation steps, removing harmful coke deposits without increasing process time.
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 enhances thermal efficiency, reduces thermal imbalances, and increases the yield of desired products by effectively removing coke deposits and eliminating the need for secondary oxidation steps, thereby improving the overall conversion process.
Implementation Method 1
fuel and oxidant exothermically react in the reactor
Implementation Method 2
combust at least a portion of the combustible non-volatiles
Implementation Method 3
exposing the first mixture to a temperature ≧800° C. in the heated reactor and abstracting sufficient heat from the reactor to convert at least a portion of the first mixture's alkane to combustible non-volatiles and unsaturated hydrocarbon
Data Source
AI summary
The invention relates to a process for converting hydrocarbons into unsaturated products such as acetylene and/or ethylene. The invention also relates to converting acetylene to olefins such as ethylene and/or propylene, to polymerizing the olefins, and to equipment useful for these processes.