Supersonic Flow Reactor Methane Pyrolysis Acid Removal
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Solution Overview
Problem
Traditional pyrolysis processes are inefficient and costly for converting methane into light olefins like ethylene, and they struggle with contaminant removal, which affects product consistency and reactor performance.
Innovation Solution
A supersonic flow reactor is used to pyrolyze methane, producing acetylene, with a contaminant removal system employing adsorbent layers to remove acids and other contaminants, ensuring low concentrations and improving process efficiency.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If traditional pyrolysis processes are used to convert methane to light olefins, then the process can operate with conventional equipment, but the conversion efficiency is low and energy consumption is high
Solution Approach 1:
The patent changes the physical parameters of the pyrolysis process by using supersonic flow conditions (Mach numbers > 1) to achieve extremely high heating rates and short residence times. This transforms the conventional slow pyrolysis into a rapid pyrolysis process, dramatically improving methane conversion efficiency to light olefins while reducing overall energy consumption through optimized heat transfer
2Productivity
If residence time in heat exchanger tubes is reduced to increase light olefin yield, then product yield improves, but heavier by-products still foul the pyrolysis tube walls
Solution Approach 1:
The patent applies the 'rushing through' principle by using supersonic flow to rapidly pass the hydrocarbon feed through the pyrolysis zone, minimizing residence time to milliseconds. This allows the desired light olefins to be produced and quickly removed before they can undergo secondary reactions that form heavier fouling by-products, thus reducing tube wall deposition while maintaining high yield
3Productivity
If supersonic flow reactor is used to pyrolyze methane, then acetylene yield increases to 40-95%, but acids and contaminants must be removed to maintain product consistency
Solution Approach 1:
The patent applies preliminary action by implementing a contaminant removal system that treats the methane feedstock before it enters the supersonic pyrolysis reactor. Acidic contaminants and other impurities are removed in advance through washing or adsorption processes, ensuring that the high-yield pyrolysis reaction produces consistent, high-purity acetylene without contamination-related variability
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 increases acetylene yield from methane to 40-95%, surpassing traditional methods, while maintaining low contaminant levels, enhancing reactor performance and product consistency.
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
a contaminant removal system employing adsorbent layers to remove acids and other contaminants
Data Source
AI summary
Methods and systems are provided for converting methane in a feed stream to acetylene. The method includes removing at least a portion of acids from a hydrocarbon stream. 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 another hydrocarbon process. The method according to certain aspects includes controlling the level of acids in the hydrocarbon stream by use of adsorbents or basic solutions.