Supersonic Flow Reactor Methane Pyrolysis for Acetylene Yield
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Solution Overview
Problem
Traditional pyrolysis processes are inefficient and costly for converting methane into valuable hydrocarbons like ethylene, and existing methods face challenges with product purity and contaminant effects in commercial-scale applications.
Innovation Solution
A supersonic flow reactor is used to pyrolyze methane, generating acetylene, which is then processed with ammonia to produce higher-value products such as pyridines, while integrating waste heat for ammonia production and utilizing catalysts to optimize reaction conditions.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If traditional pyrolysis processes are used to convert methane to hydrocarbons, then the process is simple and well-established, but the yield of valuable hydrocarbons is low and energy consumption is high
Solution Approach 1:
The patent changes the fundamental parameters of the pyrolysis process by using supersonic flow conditions instead of conventional heating methods. This creates a shock wave that rapidly converts methane to acetylene and other hydrocarbons in milliseconds, achieving higher yields while reducing energy consumption through more efficient heat transfer and shorter residence times.
Solution Approach 2:
The patent replaces the traditional thermal field-based pyrolysis system with a supersonic flow-based system. The mechanical energy of supersonic flow is converted to thermal energy through shock waves, enabling more efficient and controlled conversion of methane to hydrocarbons with better product distribution.
2Manufacturing precision
If conventional pyrolysis is used, then the process equipment is simple, but product purity is reduced due to heavier by-products fouling the pyrolysis tube walls
Solution Approach 1:
The supersonic flow process rushes the reaction through very quickly - in the order of milliseconds - before heavier by-products can form and foul the equipment. The short residence time in the supersonic flow zone prevents secondary reactions that would produce contaminants, maintaining high product purity without requiring complex cleaning systems.
Solution Approach 2:
The shock wave creation and supersonic flow occur in periodic cycles, allowing continuous production of clean hydrocarbons. The periodic nature of the shock wave generation enables consistent product quality while the rapid cycling prevents accumulation of by-products in the system.
3Productivity
If supersonic flow reactor is used to pyrolyze methane, then higher yield of acetylene is achieved, but the process complexity increases
Solution Approach 1:
The supersonic flow reactor system is designed to perform multiple functions: it creates shock waves for rapid heating, maintains supersonic flow for efficient mixing and heat transfer, and controls residence time for optimal product distribution. This multi-functionality achieves high acetylene yield while managing system complexity through integrated design.
Solution Approach 2:
By optimizing supersonic flow parameters such as Mach number, pressure ratio, and temperature profiles, the system achieves high acetylene yield. The parameter optimization allows the complex supersonic flow system to operate efficiently at commercial scales, balancing performance gains with manageable complexity.
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 method achieves a higher yield of acetylene from methane compared to traditional processes and improves product purity by removing contaminants, facilitating commercial-scale production of valuable hydrocarbons like pyridines with reduced energy consumption.
Implementation Method 1
pyrolyzing the methane in the supersonic reactor to form a reactor effluent stream portion of the hydrocarbon stream including acetylene
Implementation Method 2
The use of a supersonic flow reactor to pyrolyze a feed stream portion of a hydrocarbon stream including methane to form a reactor effluent stream portion of the hydrocarbon stream
Implementation Method 3
combining the use of supersonic flow with shock wave compression and adiabatic compression
Data Source
AI summary
Methods and systems are provided for converting methane in a feed stream to acetylene. The 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 nitrogen based hydrocarbon compounds such as pyridines. The method includes the reaction of acetylene with ammonia and controlling the ratio of acetylene to ammonia to generate the desired nitrogen based hydrocarbon compound.