Methane conversion apparatus and process using a supersonic flow reactor

Patent metadata

Field	Value
Publication number	US-2017274337-A1
Application number	US-201715618274-A
Country	US
Kind code	A1
Filing date	Jun 9, 2017
Priority date	Aug 21, 2012
Publication date	Sep 28, 2017
Grant date	—

Abstract

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.

First claim

1 . An apparatus for producing acetylene from a feed stream comprising methane comprising:
a supersonic reactor for receiving the methane feed stream and heating the methane feed stream to a pyrolysis temperature; a reactor shell of the supersonic reactor for defining a reactor chamber; a combustion zone of the supersonic reactor for combusting a fuel source to provide a high temperature carrier gas passing through the reactor space at supersonic speeds to heat and accelerate the methane feed stream to a pyrolysis temperature; an outer layer of the reactor shell for providing structural support thereto; an inner layer of the reactor shell having a thermal conductivity of between about 200 and about 500 W/m-K for conducting heat from the reactor chamber the inner layer comprising at least copper chrome, copper chrome zinc, copper chrome niobium, copper nickel and copper nickel tungsten and mixtures thereof; and one or more sensors positioned within the channel and electronically connected to one or more of a display, a monitoring system and a control system.

2 . The apparatus of claim 1 wherein the one or more sensors include pressure sensors, temperature sensors, chemical sensors, hydrogen sensors, hydrocarbon sensors, or methane sensors.

3 . The apparatus of claim 1 wherein the channel houses one or more support structures to support the inner shell relative to the outer shell.

4 . The apparatus of claim 1 wherein the channels are defined by a surface of the reactor shell.

5 . The apparatus of claim 1 wherein the channels are within a wall of the reactor shell.

6 . The apparatus of claim 1 wherein the channels axially along the reactor shell, circumferentially about the reactor shell, radially through the reactor shell, or helically about the annular reactor shell.

7 . The apparatus of claim 1 further comprising an active cooling system for maintaining the reactor portion at a temperature below the melting temperature thereof.

8 . An apparatus for producing acetylene from a feed stream comprising methane comprising:
a supersonic reactor for receiving the methane feed stream and heating the methane feed stream to a pyrolysis temperature; a reactor shell of the supersonic reactor for defining a reactor chamber; a combustion zone of the supersonic reactor for combusting a fuel source to provide a high temperature carrier gas passing through the reactor space at supersonic speeds to heat and accelerate the methane feed stream to a pyrolysis temperature; an outer layer of the reactor shell for providing structural support thereto; an inner layer of the reactor shell having a thermal conductivity of between about 200 and about 500 W/m-K for conducting heat from the reactor chamber the inner layer comprising at least copper chrome, copper chrome zinc, copper chrome niobium, copper nickel and copper nickel tungsten and mixtures thereof; and an isolation valve at an inlet of the supersonic reactor and a control system capable of detecting a change in pressure and in connection with the isolation valve.

9 . An apparatus for producing acetylene from a feed stream comprising methane comprising:
a supersonic reactor for receiving the methane feed stream and heating the methane feed stream to a pyrolysis temperature; a reactor shell of the supersonic reactor for defining a reactor chamber; a combustion zone of the supersonic reactor for combusting a fuel source to provide a high temperature carrier gas passing through the reactor space at supersonic speeds to heat and accelerate the methane feed stream to a pyrolysis temperature; an outer layer of the reactor shell for providing structural support thereto; an inner layer of the reactor shell having a thermal conductivity of between about 200 and about 500 W/m-K for conducting heat from the reactor chamber the inner layer comprising at least copper chrome, copper chrome zinc, copper chrome niobium, copper nickel and copper nickel tungsten and mixtures thereof; and a pressure relief device in the reactor shell.

Assignees

• Uop Llc

Inventors

• Bedard Robert L
• Naunheimer Christopher
• Towler Gavin P
• Leonard Laura E
• Woodcock Gregory O
• Mittendorf Donald L

Classifications

• C10G50/00

  Production of liquid hydrocarbon mixtures from lower carbon number hydrocarbons, e.g. by oligomerisation · CPC title

• B01J19/26

  Nozzle-type reactors, i.e. the distribution of the initial reactants within the reactor is effected by their introduction or injection through nozzles · CPC title

• B01J2219/029

  Non-ferrous metals · CPC title

• B01J2219/0286

  Steel · CPC title

• B01J2219/00157

  by means of a burner · CPC title