Supersonic Flow Reactor Methane Conversion
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Solution Overview
Problem
Traditional pyrolysis processes are inefficient and costly for converting methane into light olefins like ethylene, and supersonic flow reactors face challenges with mechanical failure and corrosion due to extreme operating conditions.
Innovation Solution
A supersonic flow reactor system that accelerates a methane feedstock to supersonic speeds, converting it to acetylene using a shock wave reactor with a cast reactor shell designed for high thermal shock resistance and corrosion resistance, and incorporating cooling systems to manage extreme temperatures and pressures.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If traditional pyrolysis processes are used to convert methane to light olefins, then the conversion can be achieved, but the process is inefficient and costly with low yields
Solution Approach 1:
The invention changes the operating parameters from conventional pyrolysis conditions to plasma processing conditions, utilizing electromagnetic fields and controlled temperature ranges (500-1500°C) to achieve higher yields of light olefins from methane while reducing energy consumption through more efficient energy coupling
Solution Approach 2:
The invention replaces the thermal-mechanical pyrolysis system with a plasma-based system that uses electromagnetic fields and reactive species to drive the conversion of methane to light olefins, enabling more selective and efficient reactions
2Productivity
If supersonic flow reactors operate at extreme temperatures and pressures, then higher conversion efficiency is achieved, but mechanical failure and corrosion occur
Solution Approach 1:
The invention changes the operating parameters from supersonic flow conditions to controlled plasma processing conditions, maintaining high conversion efficiency through electromagnetic field activation while operating at manageable temperatures and pressures that prevent mechanical failure
Solution Approach 2:
The invention replaces the mechanical supersonic flow system with a plasma-based system that achieves high conversion efficiency through non-thermal plasma mechanisms, eliminating the need for extreme mechanical conditions that cause failure
3Productivity
If supersonic flow reactors are used to convert methane to acetylene, then higher yield is achieved, but corrosion and mechanical failure occur due to extreme operating conditions
Solution Approach 1:
The invention changes the operating parameters from supersonic flow conditions to controlled plasma processing conditions, achieving high acetylene yield through selective plasma reactions while maintaining temperatures and pressures that prevent corrosion and mechanical failure
Solution Approach 2:
The invention creates a controlled plasma environment that acts as a protective medium, generating reactive species that drive acetylene formation while the plasma itself protects the reactor walls from direct exposure to corrosive conditions
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 system achieves a higher yield of acetylene from methane compared to traditional methods, while the advanced reactor design enhances durability and operational safety by mitigating mechanical failure and corrosion risks.
Implementation Method 1
converting it to acetylene using a shock wave reactor
Implementation Method 2
converting methane in a hydrocarbon stream to acetylene using a supersonic flow reactor
Implementation Method 3
incorporating cooling systems to manage extreme temperatures and pressures
Data Source
Figure 1
Figure 2
Figure 3~4
AI summary
Apparatus and methods are provided for converting methane in a feed stream to acetylene. A hydrocarbon stream is introduced into a supersonic reactor and pyrolyzed to convert at least a portion of the methane to acetylene. The reactor effluent stream may be treated to convert acetylene to another hydrocarbon process.