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 high operating temperatures and pressures that can lead to mechanical failure and corrosion.
Innovation Solution
A supersonic flow reactor system is designed to convert methane into acetylene, using a carrier fluid combustion zone, supersonic expansion, and a quench zone to manage extreme conditions, with a reactor shell constructed from high-temperature materials and coatings to prevent damage, and a cooling system to maintain safe temperatures.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If traditional pyrolysis processes are used to convert methane to light olefins, then the process is simple and well-established, but the conversion efficiency is low and production costs are high
Solution Approach 1:
The patent applies parameter changes by transitioning from conventional thermal pyrolysis conditions to supersonic flow conditions. The hydrocarbon stream is accelerated to supersonic speeds (Mach number > 1) through a nozzle, creating extreme shear rates and residence times that dramatically enhance methane conversion efficiency to light olefins compared to traditional pyrolysis methods
Solution Approach 2:
The patent implements dynamics by using a supersonic flow reactor where the hydrocarbon stream undergoes dynamic acceleration through a nozzle to supersonic velocities. This dynamic flow regime creates intense mixing and heat transfer conditions that improve conversion efficiency while maintaining process feasibility
2Productivity
If supersonic flow reactor operates at high temperatures and pressures to achieve high conversion efficiency, then productivity increases, but mechanical failure and corrosion risks increase
Solution Approach 1:
The patent applies segmentation by dividing the reactor into distinct functional zones: a nozzle section for supersonic acceleration, a reaction zone for methane conversion, and a cooling section. This segmentation allows each component to be optimized for its specific function and exposed to extreme conditions only where necessary, improving overall mechanical durability
Solution Approach 2:
The patent uses an intermediary cooling fluid that flows through channels in the reactor walls to absorb heat from the reaction zone. This intermediary cooling system acts as a mediator between the high-temperature reaction environment and the external environment, protecting structural components from thermal damage while maintaining high conversion efficiency
3Quantity of substance
If supersonic flow reactor operates at high temperatures to convert methane, then acetylene yield increases, but corrosion resistance requirements increase
Solution Approach 1:
The patent applies composite materials by using reactor construction materials that combine high-temperature resistance with corrosion resistance properties. The reactor is built from alloys or composite structures that can withstand both the thermal environment necessary for high acetylene yield and the chemically aggressive conditions that cause corrosion at elevated temperatures
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 resistance to high-temperature corrosion, improving operational safety and efficiency.
Implementation Method 1
a carrier fluid combustion zone, supersonic expansion
Implementation Method 2
supersonic expansion, and a quench zone to manage extreme conditions
Implementation Method 3
a quench zone to manage extreme conditions
Implementation Method 4
converting methane in a hydrocarbon stream to acetylene using a supersonic flow reactor
Data Source
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.