BRPI0710431A2 - A method for manufacturing at least one oxygenate aquila by the partial alkane oxidation reaction of an alkane-containing gas feed stream and an oxygen-containing gas feed stream. - Google Patents

Abstract

METHOD FOR DIRECT OXYGENATION OF ALKANE GASES. It is a method for the manufacture of oxygenated alkyl (for example, methanol) through partial oxygenation of alkane (methane) when using an injection retromix reaction chamber in fluid communication with a tubular flow reactor. Alkyl free radicals are induced in the retromix reaction chamber before being fed through a flow restriction deflector to the tubular flow reactor. The intermixing by injecting the feed currents shakes the reaction chamber of the retromix. In one embodiment, a variable position flow restriction deflector is moved axially in order to commensurably modify the retromix reaction chamber and the volumes of the tubular flow reactor. In another embodiment, the tubular flow reactor is tempered cooled with a variable position tempered cooling input. The method additionally provides for the condensation of the output current from the reaction system in a condensation scrubber and also the recycling of a part of the purified output current to the reactor system.

Description

METHOD FOR MANUFACTURING AT LEAST ONE OXYGENATED ALKILA THROUGH THE PARTIAL OXIDATION REACTION OF ALCANE GAS POWER CURRENT AND A GAS POWER CURRENT CONTAINING OXYGEN

BACKGROUND OF THE INVENTION

The present invention relates to a method for the reaction of natural gas and oxidant under conditions to optimize the formation of desired alkyl oxygenates (especially methanol). More specifically, the embodiments are for the reaction of a C1-C4 alkane (methane, ethane, propane and butane) in an alkylate oxygenate, and more particularly in a focal application, for direct oxidation conversion (under partial oxidation conditions). ) of methane in methanol.

Current industrial practice for methanol production is a two-step Fischer-Tropsch type chemical process. The first step is the endothermic reforming of methane from natural gas to carbon monoxide and hydrogen, followed by a second step consisting of a solid catalyzed reaction between carbon monoxide and hydrogen to form methanol. This technology is energy intensive, and the process economy is unfavorable for all except large-scale methanol plants.

Various methods and apparatus for converting methane to methanol are known. Performing a conversion of the vapor phase of methane to a synthesis gas (mixture of CO and H2) with its subsequent catalytic conversion to methanol is known, as described, for example, in Karavaev MM, Leonov BE, et al. Technology of Synthetic Methanol ", Moscow," Chemistry "1984, pages 72-125. However, in order to practice this process, it is necessary to provide complicated equipment, to meet high gas purity requirements, to spend high amounts of energy to obtain and purify the synthesis gas, and a significant number of intermittent process stages, and for medium and small companies with a capacity of less than 2,000 tonnes / day this is not economically viable .

Russian Patent No. No. 2,162,460 includes a hydrocarbon-containing gas source, a compressor and heater for gas compression and heating, and an oxygen-containing gas source with a compressor. It additionally includes successively arranged reactors with alternating mixing and reaction zones and a device for providing hydrocarbon-containing gas in a first reactor mixing zone and oxygen-containing gas in each mixing zone, a recovery heat exchanger for cooling the reaction mixture through a wall by a cold hydrocarbon-containing gas stream from the heated hydrocarbon-containing gas to a heater, a refrigerant-condenser, a partial condenser for the separation of waste gases and liquid products with a subsequent separation of methanol, a pipe for the supply of residual gas to the initial hydrocarbon-containing gas and a pipe for the supply of residual oxygen-containing products in the first reactor mixing zone.

In this apparatus, however, rapid heat removal from the highly exothermic oxidation reaction of the hydrocarbon-containing gas is not feasible because of the inherent limitations of the heat exchanger. This leads to the need for a reduction in the amount of hydrocarbon-containing gas provided and further reduces the degree of conversion of the hydrocarbon-containing gas. Moreover, even with the use of oxygen as an oxidant, it is not possible to provide efficient recirculation of the hydrocarbon-containing gas due to the rapid increase in carbon oxide concentration. A significant part of the oxygen supplied is wasted for the oxidation of CO to CO2 and thereby further reduces the degree of conversion of the initial hydrocarbon-containing gas to useful products and provides additional overheating of the reaction mixture. The apparatus also requires the burning of an additional amount of the initial hydrocarbon-containing gas in order to provide the utility needs of a liquid product rectification. Since it is necessary to cool the gas-liquid mixture after each reactor for liquid separation and subsequent heating before a subsequent reactor, the apparatus is substantially complicated and the number of units is increased.

Another method and another apparatus for producing the

Methanol are described in U.S. Patent 2,200,731, wherein the heated compressed hydrocarbon-containing gas and the compressed oxygen-containing gas are introduced into successively arranged reactor mixing zones, and the reaction is carried out with controlled heat uptake by cooling the reaction mixture with water condensate so that steam is obtained, and a degree of cooling of the reaction mixture is regulated by vapor exhaust parameters, which is used in the rectifying stage of the liquid product.

Other patent documents such as U.S. Patent Nos. 2,196,188, 2,722,553, 4,152,407, 4,243,613, 4,530,826, 5,177,279, 5,959,168 and International Publication WO 96/06901 describe additional solutions for the transformation of hydrocarbons.

There is also a need for a one-step process that is also suitable for small scale processing, overcoming the process limitations of the Fischer Tropsch method and also making "stranded gas" a valuable product. This approach employs a homogeneous partial gas phase oxidation reaction carried out on contact with natural gas and an oxidant, with the oxidant as a limiting reagent. The most abundant products are methanol and formaldehyde, which come from methane, the main component of natural gas. Smaller amounts of ethanol and other oxygenated organic compounds are formed by the oxidation of higher methane, ethane, propane and hydrocarbons which are all minor constituents of natural gas. These reaction products are all liquids, and are transportable to a central location for separation and / or subsequent use as fuels or as chemical intermediates. A key feature of such processes is that process chemistry can be performed in the field at remote locations.

U.S. Patent No. 4,618,732 ("Direct conversion of natural gas to methanol by controlled oxidation" to Gesser, et al.) Describes a process for converting natural gas to methanol. Selectivity for methanol is indicated as result of careful premixing of methane and oxygen together with the use of glass-lined reactors to minimize interactions with processing equipment during the reaction.The need for mixing prior to entering a reactor for reaction initiation is indicated in following excerpt:

"Gas mixing preferably takes place in a relatively small volume" crossover "or premix chamber and then passes through a short pre - reactor section before entering the heated reaction zone. However, when mixing gases at high pressure in a relatively small volume, laminar flow often occurs with oxygen or air, forming a narrow homogeneous current within the general flow of natural gas. Oxygen or air has little chance of dispersing through the reaction current before reaching the reaction zone. Without wishing to be bound by theory, when this occurs, it is postulated that natural gas is initially oxidized to methanol, which is further oxidized, on the periphery of the oxygen stream, that is, in an oxygen rich environment, to higher oxidation products. "

U.S. Patent no. No. 4,618,732 to Gesser also emphasizes the need to maintain the reaction from initiation until mixing is complete (--- mixture of oxygen and natural gas prior to introduction into a reactor).

U.S. Patent no. 4,982,023 ("Oxidation

Han, et al.) establishes that a plurality of reactions are occurring in the direct oxygenation of methane to methanol. In this regard, U.S. Patent No. 4,982,023 indicates some consideration regarding the problems. of reaction kinetics in the discussion of the subject of this patent:

"The mechanism of methanol formation is believed to involve the methylperoxy radical (CH3OO) that abstracts methane hydrogen. Unfortunately, so far, yields per pass have been limited. This limited yield has been rationalized as a result of the low reactivity of the bonds. of CH in methane vis-à-vis the higher reactivity of the primary oxygenated product, methanol, which results in selective formation of deep oxidation products CO and CO2 when attempts are made to increase conversion. "

U.S. Patent no. 4,982,023 also makes it clear that methane and oxygen must be pre-mixed prior to the reaction, as noted in the following passage: "... natural gas and oxygen or air are kept separate until mixed immediately before being mixed. However, if desired, oxygen and natural gas may be pre-mixed and stored together prior to the reaction. "

Unfortunately, laboratory results regarding methanol selectivity and single position yield for non-catalyzed direct oxygenation of methane in methanol have not been reliably doubled when calculating reaction technology for tailor-made systems. The need for an efficient and cost-effective method that allows for non-catalyzed direct oxygenation of methane in methanol has not yet been met.

SHORT DESCRIPTION

Accordingly, an object of the present invention is to provide a method for manufacturing at least one alkyl oxygenate (e.g., without limitation, ethanol, formaldehyde and / or ethanol) by the partial alkane oxidation reaction (e.g. without limitation, methane, ethane, propane and butane) from an alkane containing gas feed stream and an oxygen containing gas feed stream. The method comprises providing a reactor system having a injectably retromix reaction reaction chamber in fluid communication with a tubular flow reactor; feeding the alkane-containing feed stream and the oxygen-containing feed stream into the injectably mixed back-mix reaction chamber; inducing the formation of alkyl free radicals in the injectably mixed back-mix reaction chamber to result in a stream of injectable mixed back-mix reaction chamber product comprising oxygen, alkane and at least a portion of the alkyl free radicals; feeding the product stream from the back mix reaction chamber injectably mixed with the tubular flow reactor; and the reaction of the product stream from the injectably retromix reaction chamber into the alkylate oxygenate in the tubular flow reactor.

In one embodiment, feeding the alkane-containing feed stream and the oxygen-containing feed stream injectably mixes the alkane-containing feed stream and the oxygen-containing feed stream to turbulently agitate the injectably mixed back-reaction reaction chamber.

In another embodiment, the feed stream of the injectably mixed back-mix reaction chamber product fluidly carries the back-mix product stream of the reaction chamber through a flow restriction deflector.

In one aspect, the reactor system has an induction and reaction spacetime corresponding to a combined feed rate of the alkane-containing feed stream and the oxygen-containing feed stream of no more than 40 seconds.

However, in another embodiment, a tubular flow reactor has a tubular flow reactor inlet and a tubular flow reactor outlet, the method further comprising quenching cooling of a tubular flow reactor with a current of refrigerant gas received from a refrigerant gas inlet disposed at a position between a tubular flow reactor inlet and a tubular flow reactor outlet. In one aspect of this, cooling is performed by axially adjusting the position of the refrigerant inlet during operation of the tubular flow reactor.

In various embodiments, the tubular flow reactor discharges a reaction product stream from the tubular flow reactor outlet and the method further comprises scrubbing the reaction product stream with a liquid absorber to remove methanol from the reaction product stream. . In other aspects of various embodiments, the absorbent additionally absorbs carbon dioxide and / or formaldehyde from the reaction product stream. However, in another aspect of various embodiments, the method further comprises recycling a scrubber recycle stream to the alkane-containing feed stream (preferably to provide a weight ratio of about 4: 5a to about 20:21 alkane). in the alkane containing feed stream).

However, in another embodiment, the injectably mixed backmix reaction chamber has a backmix reaction chamber housing and a bulkhead in a slidably sealed interface to the backmix reaction chamber housing, wherein the reaction chamber of Injectably mixed back-mix has an internal volume of the injectably mixed back-reaction reaction chamber defined by the back-mix reaction chamber housing and the bulkhead, and the back-mix reaction chamber housing has a portion of the shell in an arrangement opposite the bulkhead. In these embodiments, the induction further comprises (a) sliding the bulkhead displacement during real-time operation of the reactor system to progress within the casing of the injectably mixed back-reaction reaction chamber toward the casing portion to measurably decrease the internal volume of the injectably mixed back mix reaction chamber or (b) the slidingly displaceable bulkhead during real-time operation of the reactor system within the injectably mixed back mix reaction chamber enclosure to retract away from the portion of the casing to thereby commensurably expand the internal volume of the injectably mixed back-reaction reaction chamber.

However, in another embodiment, feeding the alkane-containing feed stream further comprises pressurizing the alkane-containing gas feed stream with a centrifugal blower prior to entry into the injectably mixed back-mix reaction chamber.

New features which are considered as features for the present invention are set forth in detail in the appended claims. The invention itself, by its construction and method of operation together with the additional objects and advantages thereof, will be better understood from the following description of specific embodiments when read with reference to the accompanying drawings.

BRIEF DESCRIPTION OF DRAWINGS

Figure 1 schematically shows a system of an apparatus for producing alkyl oxygenate (e.g., without limitation, methanol) according to the present teachings;

Figures 2 and 3 are views illustrating concentrations of oxygen, formaldehyde and methanol during the reactions according to the prior art and according to the present invention accordingly;

Figure 4 is a graph depicting the resulting system oxygenates as a function of the recycle ratio;

Figure 5 is a C1-C4 alkane for the alkyl oxygenate plant according to the teachings of the present invention;

Figure 6 represents an optional oxygen production plant shown in Figure 5;

Figure 7 depicts a gas processing portion of the plant shown in Figure 5;

Figure 8 represents the liquid processing portion of the plant shown in Figure 5;

Figure 9 represents another alternative C1 -C4 alkane (e.g., without limitation, methane) for the alkyl oxygenate plant (e.g., without limitation, methanol) according to the teachings of the present invention;

Figure 10 represents, however, another alternative C1-C4 alkane (e.g., without limitation, methane) for the alkyl oxygenate plant (e.g., without limitation, methanol) according to the teachings of the present invention;

Figure 11 represents, however, another alternative C1-C4 alkane (e.g., without limitation, methane) for the alkyl oxygenate plant (e.g., without limitation, methanol) according to the teachings of the present invention;

Figure 12 shows a simplified cross-sectional view of one embodiment of a reactor system having an injectably mixed back-mix reaction chamber coupled to a tubular flow reactor;

Figures 13A and 13B show simplified cross-sectional views of the details in modifying the internal volume of the injectably mixed back-mix reaction chamber of Figure 12;

Figure 14A shows a simplified cross-sectional view of an alternative design for the injectably mixed back-mix reaction chamber of Figure 12;

Figure 14B shows a view of the injectably mixed back-mix reaction chamber of Figure 12 with modified internal volume relative to that shown in Figure 12;

Figures 15A and 15B show a simplified cross-sectional view of a "hairbrush" fluid application insert for the injectably mixed back-mix reaction chamber of the reactor system embodiments of Figures 12 and 20;

Figure 16 shows a simplified cross-sectional view of internal fluid positions for the tapered fluid application recess for the injectably mixed back-mix reaction chamber of the reactor system embodiments of Figures 12 and 20;

Figures 17A and 17B show a simplified cross-sectional view of details of the deflector and positioning at the interface between the injectably mixed backmix reaction chamber and the tubular flow reactor of the embodiments of the reactor system of Figures 12 and 20;

Figures 18A and 18B show a simplified cross-sectional view of the details and positioning for a variable position rough cooling inlet of the reactor system embodiments of Figures 12 and 20;

Figures 19A to 19C show a series of temperature profiles for a tubular flow reactor of the embodiments of the reactor system of Figures 12 and 20;

Figure 20 shows a simplified cross-sectional view of an alternative embodiment of a reactor system having an injectably mixed back-mix reaction chamber coupled to a tubular flow reactor;

Figure 21 shows details of the shield / deflector for an embodiment of the interface between the injectably mixed back mix reaction chamber and the tubular flow reactor of the reactor system embodiments of Figures 12 and 20;

Figures 22A-22C show the details of the axial positioning for the interface between the injectably mixed backmix reaction chamber and a tubular flow reactor of the embodiment of the reactor system of Figure 20;

Figure 23 shows further detail in the blast cooling inlet for the realization of the reactor system of Figure 20;

Figures 24A and 24B show details of the axial view for carrying out the reactor system of Figure 20; and

Figures 25A and 25B show views of tubular flow reactor systems having injectably mixed inlet zones, multi-position quenching and multi-position temperature detection.

DESCRIPTION OF PREFERRED EMBODIMENTS

The following non-limiting definitions and guidelines should be taken into consideration when reviewing the description of the invention presented herein.

Titles (such as "Introduction" and "Brief Description") and subtitles (such as »Amplification") used in the present invention lend themselves only to the general organization of topics within the description of the invention and do not lend themselves to limiting the description. In particular, the subject matter described in the "Introduction" may include technological aspects within the scope of the invention and may not constitute a citation of the prior art. The subject matter described in the "Brief Description" is not an exhaustive description. or completes the entire scope of the invention or any embodiments thereof.

The citation of references in the present invention does not constitute an admission that such references are of the prior art or of any relevance to the patentability of the invention described herein. All references cited in the "Description" section of this descriptive report are hereby incorporated by reference in their entirety.

The description and specific examples, while indicating the embodiments of the invention, are for illustration purposes only and are not intended to limit the scope of the invention. In addition, citation of multiple realizations that have the stated characteristics does not exclude other realizations that have additional characteristics or other embodiments that incorporate different combinations of the stated characteristics.

As used herein, the words "preferred" and "preferably" refer to embodiments of the invention that have certain benefits under certain circumstances. However, other embodiments may also be preferred under the same or other circumstances. Furthermore, citation of one or more preferred embodiments does not imply that other embodiments are not useful and is not intended to exclude other embodiments from the scope of the invention.

As used in the present invention, the word 'includes' and variants thereof lends itself to being non-limiting, so that citation of items in a list does not lend itself to excluding other similar items which may also be useful in compositions, materials, in the devices and methods of the present invention.

The examples and other embodiments described in the present invention are exemplary and are not intended to limit the description of the full scope of the compositions and methods of the present invention. Changes, modifications and equivalent variations of specific embodiments, materials, compositions and methods may be made within the scope of the present invention, with substantially similar results.

The embodiments relate to the direct oxygenation conversion of at least one C1-C4 alkane into at least one alkylate oxygenate. The conversion of direct oxygenation from methane to methanol is a goal of focal conversion technology.

An apparatus for producing methanol according to the present invention has a reactor 100 which facilitates gas phase oxidation of a hydrocarbon-containing gas as shown in Figure 1. In the overview of reactor 100, a heated hydrocarbon-containing gas stream ( 120 and heater 136) and a line 29 oxygen-containing gas are introduced into reactor 100. As explained in detail below, the oxygen-containing gas preferably has an oxygen content of more than 80% to reduce the accumulation of oxygen. inert gases by the recycling process.

The reactor 100 additionally and optionally receives a quench-cooled cold hydrocarbon-containing gas stream from valve 120 and heat exchanger 121 to reduce the reaction temperature during operation of the apparatus.

The apparatus has a device 114 for cooling the reaction mixture stream prior to separation. Additionally, partial condenser 122 incorporates a gas-liquid heat exchanger to further reduce the temperature of the products. Condenser 122 separates H 2 O and alcohols from a hydrocarbon-CO2 mixture. Partial capacitor 122 is preferably isobaric, not isothermal, to prevent pressure losses. The reaction product stream enters and a liquid stream and a gaseous stream exit condenser 122. Block 139 represents equipment that is configured to separate contaminants and products from a hydrocarbon-containing recycle gas component. In this regard, equipment 139 is configured to remove CO2 from the reduced product stream. Equipment 139 may be in the form of a relief valve, absorber, membrane separator or an adsorbent. It is envisaged that equipment 139 may be used to regulate the percentage of other non-reactive components such as N2 with, for example, a relief valve.

In the event that the system is configured to recover formaldehyde, the reduced gaseous product stream exits isobaric condenser 122 and is passed to scrubber 134. Other potential methods that may be employed employ materials such as various known amines to remove CO2 and Formaldehyde.

To meet the minimum absorption requirements, modification of the methanol flow rate or scrubber column operating temperature may be used. If operation at extremely low absorbent flow rates is desirable, then a lower temperature may be used, for example 0 ° C. If operation at ambient temperatures or at temperatures achievable by cooling water is desirable, then a high flow rate may be used, for example, ten times the flow rate at 0 ° C. In both situations, the turgid methanol 14 absorbent stream is completely regenerated by the formaldehyde distillation column 138. Optionally, the scrubber stream 134 may be passed through the condenser 122 to provide product stream cooling and preheat the product. methanol recycling to increase the energy efficiency of the formaldehyde distillation column 138.

The reactor 100 is connected with a compressor 124 and heater 126 for supplying the compressed and heated oxygen containing gas. The crude hydrocarbon-containing gas is mixed with the scrubber's clean hydrocarbon gas 134 and heated using a heater 136. In the event that the crude hydrocarbons have a high CO2 content, the crude hydrocarbons may be mixed with the product hydrocarbon stream. condenser 122 before entering the scrubber 134 to remove contaminating gases before entering the reactor.

The apparatus further has a methanol grinding unit including an evaporation cylinder 132, a rectifying column 128 and a container 130 from which methanol is provided for further storage or processing. This rectifying column 128 is used to separate methanol (light key component) from ethanol (heavy key component) and water (not a key component). As noted above, it is desirable for a portion of the heavy key component to enter the distillate stream (as dictated by the commercial formalin specification). For methanol rectification 99% or more purity is typical and 99.999% is feasible with multiple columns. Stream 4 enters the column and distillate in stream 5 and the bottom in stream 8 exits the column in the liquid phase. Stream 8 has some amount of ethanol (and perhaps methanol if ultrapure methanol is produced) and will be used as the basis of the aqueous composition of the commercial formalin stream (stream 11 and formalin storage 191). In this way, part of the ethanol is recovered before the remainder is discarded into the net residual stream.

An evaporation cylinder 132 for the removal of CO2 and formaldehyde from the liquid stream is disposed between column 128 and condenser 122. The purpose of evaporation cylinder 132 is to drop the pressure to an appropriate level prior to entry into the column. methanol 128 and substantially remove all dissolved gases, typically CO2 and formaldehyde, from the liquid product stream.

In operation, the crude hydrocarbon-containing gas stream having a content of, for example, up to 98% methane and the reduced hydrocarbon product stream are coming from a gas preparation plant or from any other heater feed 136, wherein they are heated to a temperature of 430-470 ° C. The heated hydrocarbon-containing gas is then passed to reactor 100. The compressed air with pressure, for example, 7-8 Mpa, with a ratio of 80% to 100% and preferably 90% to 95% oxygen. , is also provided by compressor 124 to reactor 100. The oxidation reaction of methane in methanol and / or formaldehyde occurs in reactor 100. Between 2% and 3% O2 of the total reactant volume is reacted with the hydrocarbon-containing gas stream. heated as previously described. To limit the amount of N2 within the system, for example, to less than 30% -40%, or to reduce the required purge stream size to achieve it, the O2 stream is preferably substantially pure, thereby limiting the amount of N2 that enters the system.

An optional second stream of cold refrigerant (or, in other words, a coolant at a lower temperature than gases) in the reactor is provided to reactor 100 as previously outlined. This current is regulated by the regulating device (valve) 120, which may be formed as a known gas supply regulating device, a regulating valve, or the like. This cold stream may, for example, be composed of a crude hydrocarbon stream, a recycled stream or a portion or combination thereof. The regulator is configured to adjust the volume or pressure of the cold hydrocarbon-containing gas based on system parameters such as, but not limited to, the pressure, temperature, or percentages of the reaction product at an additional downstream location in the system. .

Refrigerant, which comes from a refrigerant feed, functions to reduce the temperature of partially oxidized methane to reduce oxidation or continued decomposition of formaldehyde. This coolant can be any material that can be easily separated from the reaction product stream. For example, as best described below, the refrigerant may be a hydrocarbon or unheated methane containing the gas stream.

Preferably, the refrigerant may be any non-oxidizing material readily separated from the reaction products. In this regard, the refrigerant may be gas, an aerosol or a misty liquid of, for example, CO2, formaldehyde, methanol, water and / or steam. It is further contemplated that the coolant may additionally be a mixture of recycled reaction products, water, steam, and / or crude hydrocarbon gases.

Depending on the intended mode of operation of the apparatus, particularly the production of methanol or methanol and the desired formaldehyde, the reaction mixture is reacted in the reactor without the introduction of cold hydrocarbon gas if essential / exclusive methanol production is desired. . The introduction of cold hydrocarbon-containing gas is used when methanol and formaldehyde are desired as products. By introducing the cold hydrocarbon gas, the reaction temperature is reduced to, for example, 30-90 ° C, in order to preserve the formaldehyde content in the separate mixture by reducing the decomposition of formaldehyde in CO2.

The reaction mixture is provided to the heat exchanger 114 for transferring heat to the reactor inlet stream of the reaction mixture exiting the reactor, and, after further cooling, is passed to the partial condenser 122. Low and high volatility (dry gas and crude liquid, respectively) is performed in partial condenser 122, which can absorb at least part of the formaldehyde in the gross liquid stream, if desired. Dry gas is sent to a scrubber 134, while crude liquids from condenser 122 are provided to evaporation cylinder 132.

The scrubber 134 works to remove CO2 and formaldehyde from the dry gas stream. In this regard, scrubber 134 uses H 2 O and methanol at a pressure of 7-8 MPa and approximately O = C and approximately 50 ° C to absorb CO2 and formaldehyde. Once CO2 and formaldehyde are removed, the reduced hydrocarbon gas stream is recycled by mixing the reduced stream with the crude hydrocarbon-containing gas stream before or inside the reactor if desired. The reduced or crude hydrocarbon streams, individually or in combination, are then introduced into the reaction chamber 100 after being heated by heat exchanger 116 and heater 136 as previously described.

Rectifying column 138 is used to separate carbon dioxide (not a key component) and formaldehyde (light key component) from methanol (heavy key component) and water (not a key component). Turbulent methanol vapor, stream 14, enters rectifying column 138 and is separated into formaldehyde distillate stream 16 and lower stream 15. Some amount of methanol in the distillate stream is desirable since methanol is used. as a stabilizer for commercial type formalin production (6-15% alcohol stabilizer, 37% formaldehyde and the rest consists of water). By leaving a portion of the key component weighed in the distillate stream, separation is more easily achieved; furthermore, process losses typically experienced during absorbent regeneration are subsequently nullified as methanol within the distillate is used for formalin production. Stream 15 is supplemented by stream 31 to replace any methanol that is transferred to the distillate stream, stream 16. The combination of stream 31 and stream 15 results in stream 17, which then returns to scrubber 134 as the regenerated methanol absorber. . Meanwhile, the formaldehyde distillate, stream 16, combines with the evaporator cylinder vapors .132, stream 7, to form a mixture of formaldehyde, methanol and carbon dioxide.

Formaldehyde, water, methanol and CO2 removed by scrubber 134 are passed to formaldehyde rectifying column 138. Column 138 removes formaldehyde and CO2 from the methanol-water stream. Small amounts of methanol are combined with the methanol produced and introduced into the scrubber 134 to remove additional amounts of CO2 and formaldehyde from the reduced hydrocarbon stream.

The free or non-aqueous formaldehyde may then remain in the gas phase by the operation of the isobaric condenser 122. The liquid methanol product stream, or crude liquids, therefore comprises methanol, ethanol and water since the formaldehyde remains in the gas stream. In this case, the liquid stream leaving the isobaric capacitor 122 may bypass the formaldehyde rectifying portion of the process and enter the methanol rectifying column after it has optionally passed

through the evaporation cylinder 132.

Figures 2 and 3 show diagrams of the concentration of oxygen, formaldehyde and methanol in reactions with and without refrigerant, respectively.

As can be seen in Figure 2, approximately two seconds after the reaction time, oxygen is essential and completely reacted. At this time, the reaction temperature reaches its maximum, and methanol and formaldehyde are produced in their respective proportions within the reaction mixture. Methanol is a more stable product at the end of the reaction and its concentration remains substantially stable after reaching its maximum concentration. Formaldehyde is less stable and therefore, with a rise in temperature (the temperature rises until oxygen is essential and completely consumed), its concentration is reduced in part.

In the reaction with the coolant shown in Figure 3, by introducing cold gas when methanol and formaldehyde formation is terminated, the temperature of a final reaction period is reduced to inhibit formaldehyde decomposition.

Figure 4 represents a graph illustrating the

oxygenate to the system as a function of the relationship between the recycling of hydrocarbon gases. Shown is a graph illustrating the utilization of Michigan Antrim gas which has 97% CH4 and 1% N2. In this respect, the graph shows a significant increase in product yield using the same input stream and little increase in financial costs. Since the system efficiently controls pressure and integrates process power utilization, power requirements are minimized, thereby increasing the overall system economy.

Figure 5 depicts an alternative methane for methanol plant 150. Plant 150 is positioned to process gas methane being discharged from a combined oil and gas field 152 or gas field 154. Plant 150, which is preferably located near the wellbore, is generally comprised of a gas processing plant 156, a liquid processing plant 158 and an oxygen production plant 160. Utility and wastewater treatment plants 162 and 164 are additionally associated with plant 150.

As shown in Figure 6, an optional oxygen production plant 160 may be used to assist in regulating partial oxidation of the hydrocarbon stream in reactor 100. Oxygen production plant 160 has a compressor 161 coupled to a heat exchanger 163 which works to prepare compressed oxygen for injection to a plurality of absorbers 165. After passing through the absorbents, the produced oxygen stream is compressed and sent directly to reactor 100.

Referring generally to Figure 7, the gas processing portion of plant 156 generally functions as described above (see Figure 1). In this regard, gas processing plant 156 has compressors 170 and 172 to increase the pressure of a clean inlet hydrocarbon stream 174. This stream 174 is then split and reacted with oxygen in reactor 100 to partially oxidize methane. , as described above.

It is anticipated that parameters such as reaction time and temperature and pressure within the reactor can be adjusted to selectively control the amount of CO2, H2O, formaldehyde and methanol that is produced in reactor 100. reactor are then transferred to the liquid processing plant 158.

As shown in Figure 8, liquid processing plant 158 generally functions as described above to separate methanol and formaldehyde from the reaction product stream 176. Associated distillers, mixers and evaporation cylinders that are used are shown. to separate the constituent materials from the reaction product stream as described in detail above. Specifically, CO2 is removed from the reaction product stream such as methanol and, if desired, formaldehyde. The scrubber 134 (see Figure 5) prevents the accumulation of CO2 and allows the physical uptake of formaldehyde. The scrubber 134 may utilize a mixture of methanol and water to physically absorb the formaldehyde and CO2 from the hydrocarbon gas recycling circuit 135. The efficiency of the scrubber 134, which can operate properly without refrigeration, is possible due to the high operating pressure of the scrubber. recycling circuit 135. This is opposed to the low cryogenic temperatures used by traditional absorption processes. The gases enter the scrubber 134 as a "dirty" gas with some amount of formaldehyde and CO2 present. These components will be present only in relatively dilute amounts, so that the absorbing function of methanol is also relatively small.

As previously mentioned, it is anticipated that the reactor output may be selectively adjusted to minimize the amount of formaldehyde being produced by the gas portion of the plant 156 process. Although CO2 may be dispersed, it is specifically anticipated that the CO2 of the products The reaction valve can be injected at a predetermined distance from the well into the ground to increase the well output. In this regard, it is envisaged that CO2 may be injected at any appropriate distance from the well to allow for increased underground pressures to increase gas or oil output from the well. In addition, it is anticipated that CO2 may be injected into the well bore enclosure or in the area near the well bore to increase gas or oil output and the gas production well.

Although shown as a land-based plant, it is specifically envisaged that plant 150 may be associated with offshore oil rig. In this regard, plant 150 should be in offshore equipment or within a predetermined short distance from equipment, such as immediately adjacent to offshore equipment on a floating platform. In the example of offshore equipment producing natural gas, it is anticipated that methanol converted from the methane-containing hydrocarbon stream will be injected into a second portion of the methane-containing hydrocarbon stream to increase the flow of hydrocarbon stream from the hydrocarbon stream. Oil well offshore. This methanol is injected to reduce hydrate formation within the pipe. Methanol associated with natural gas should then be removed from the hydrocarbon-containing stream after the stream reaches the shore.

It is further envisaged that any of the other reaction products, namely CO2, water or methanol, may be injected directly into the hydrocarbon-containing underground formations surrounding the platform or an earth-based well. Specifically, it is anticipated that methanol may be injected into the hydrate structures surrounding the well in order to increase natural gas output from a natural gas production well.

Returning briefly to Figure 5, it is anticipated that CO2 may be injected into one portion of the well, with methanol or other reaction products injected into other portions of the well. In situations where natural gas may be stranded or may have nitrogen contents greater than 4%, facilities may be provided to control the accumulation of nitrogen in the recycling loop. When outputs from any particular well 152, 154 are low, it is envisaged that a single plant 100 having a truncated process may be utilized. In these situations, only portions of the facility related to partial oxidation of the hydrocarbon stream and associated facilities for CO2 removal will be used near the well.

CO2 removed can be collected, dispersed or reinjected into the earth. Immediately after removal of the natural gas and associated CO2 from the scrubber, the remaining liquid products may be transported in liquid form from the well site to another location for the separation of formaldehyde, methanol and water from the waste stream. In this regard, it is envisaged that a centralized liquid processing plant for finalizing liquid process processing (158) may be located at a significant distance from the stranded natural gas locations. This allows the use of a centralized liquid process facility 158. It is also envisaged that reactor conditions may be adjusted to produce a liquid phase containing a commercial type of formalin.

Another embodiment of process 900 is shown in Figure 9. Air 902 is introduced into compressor 934 and is then cooled in heat exchanger 904 for application to a nitrogen separator 906 or a nitrogen separator 908. Oxygen feed It is stored in tank 962 and is compressed with compressor 910 for introduction as an oxygen-containing feed stream into reactor system 914 after heating in heater 912. The raw feed containing alkane 92 6 (at least one C1-C4 alkane, (mainly methane or natural gas) is compressed on compressor 928 and is mixed with scrubber alkane recycling 900 for additional pressurization on compressor .922 and thermal cross-exchange with reactor product stream reactor 936 on heat exchanger 930 The recycle stream preferably provides a weight percent ratio of from about 4: 5 to about 20:21 of alkane in the stream. and alkane containing feed to the reactor. In one embodiment, where the scrubber 920 is pressurized to a pressure in the order of reactor system 914 (see Figures 12 to 24B and the accompanying text for additional details in reactor drawings for reactor system 914), compressor 922 can be a centrifugal blower (non-positive displacement compressor). After the thermal cross-exchange with the reactor product stream reactor 93 6 on heat exchanger 93 0, the combined raw alkane and recycle stream are heated on heat exchanger 93 2 to provide an alkane-containing feed stream to the system. 914. The embodiments of the 914 reactor system are further described in Figures 12 - 24B. The .920 scrubber operates to absorb carbon dioxide and alkyl oxygenates (e.g., without limitation, methanol, ethanol and formaldehyde) by providing a recycle stream for combination with fresh alkane to provide a feed stream to 922 compressor. A purge on valve 924 removes non-reactive inert components (eg, without limitation, nitrogen) from the scrubber reactor process circuit to increase efficient utilization of the 914 reactor system. reactor system 914 is also optionally activated from valve 938. The scrubber bottom 920 is sent to evaporation cylinder 918 where elevated steam 942 separates from product stream 94 (comprising, for example, and without limitation, methanol, ethanol and formaldehyde). Furnace or thermal oxidizer 916 oxidizes waste gases for discharge into the atmosphere. Process 900 is useful for providing a liquid material for further processing elsewhere in the purified alkane oxygenates or for providing a useful alkane oxygenate mixture for a fuel or other similar use where exact purity is not essential.

Figure 10 shows another embodiment of process 1000 with a front end process circuit essentially similar to process 900 shown in Figure 9, but incorporating an in-situ distillation system 1002 for separating methanol in steam 1004 (for the absorbent in purified water in stream 1006 for use in disassembly cylinder 1012 and generation of purified methanol 1008 and residual stream 1010. Disassembly cylinder 1012 provides for initial separation of liquid from reactor product stream prior to introduction of the rest of the reactor product stream in the debugger.

Figure 11 shows an embodiment of process 1100 for generating a methanol and formaldehyde product stream with a front end process circuit essentially similar to process 900 shown in Figure 9, but incorporating an in situ formaldehyde distillation system 1110 and a methanol distillation system 1108 to generate the methanol product stream 1102. The methanol distillation system stream 1108 cools the upper part of the formaldehyde distillation system 1110 to separate carbon dioxide (product stream 1106) and the formaldehyde (product stream 1104) in the absorber-mixer 1116. A methanol recycle stream to the scrubber is extracted from the methanol distillation system 1108 and cooled in chiller 1112 to provide a high efficiency scrubber to condense the product stream. of the reactor. Furnace or thermal oxidizer 1114 oxidizes a purge to remove non-reactive inert components (eg, without limitation, nitrogen) with some alkane (methane) from the scrubber reactor process circuit and thereby to increase the efficient utilization of the reactor.

While a traditional tubular flow reactor may be used with any of the processes described above as a reactor 100 and / or a reactor 914, preferred reactor embodiments are described in the discussion of Figures 12 to 24B.

Returning now to a deeper consideration of reaction kinetics and additional realizations to provide an improved reactor system for performing the full reaction for partial oxidation of natural gas to methanol, formaldehyde and other oxygenates, several compact production facilities have been described in Figures 1 to 11 which are suitable for small and isolated natural gas (stranded gas) feeds. New reactor systems for these processes are also described starting with Figure 12 and, more specifically, as noted in Figures 12 and 20. Initial considerations in these reactor designs derive from the nature of the total direct oxygenation reaction itself.

In the general view, the reaction method comprises passing a mixture of natural gas and oxidant through a continuous flow reactor system and heated under conditions to optimize methanol formation and to manipulate reactor temperature, pressure, and pressure. total and fuel (eg, without limitation, natural gas) to the oxidant ratio to control the relative quantities of reaction products. The reaction is a partial oxidation of a C1-C4 fuel, such as natural gas, an oxidant, oxygen, air or other appropriate oxygen-containing compound (preferably oxygen in the air or, more preferably, oxygen). ). The mixture contains substantial excess fuel (e.g., without limitation, natural gas) to prevent complete combustion for unwanted products such as carbon dioxide and water.

The reaction is a branched and exothermic chain reaction. Chain branching causes an acceleration of the reaction rate through the quadratic growth of chain carriers. Reactions of this type are characterized by an induction period during which chain carrier concentrations accumulate to the point where a rather rapid rise in reaction speed and temperature occurs. The rather rapid rise in the speed of action is due to the quadratic growth rate of chain carriers and the rather rapid rise in temperature is due to the increase in the heat generation rate that follows the speed of the reaction. Complete consumption of oxidant, the limiting reagent, occurs before the fuel (eg, without limitation, natural gas) is fully consumed, which limits the rise in temperature. The relationship between oxidant and fuel (eg, without limitation, natural gas) is arranged so that selectivity for methanol formation is optimized.

Reaction conditions favoring better selectivity for methanol and other oxygenates are as follows. The composition of the reaction mixture, after combining the alkane-containing feed stream and the oxygen-containing feed stream, should be from about 1 mol% to about 10 mol% oxidant, more preferably from about 2 mol% to about 5 molar. Molar% of oxidant and most preferably approximately 2.5 Molar% of oxidant. The total gas pressure in the reactor system should be in the range of about 6 MPa to about 10 MPa, more preferably from about 7.5 MPa to about 9 Mpa, and most preferably about 8 Mpa. The wall temperature of the reactor system should be in the range of approximately 600 K to approximately 900 K, more preferably in the range of approximately 723 K to approximately 823 K. The total residence time of the reactor should be in the range of approximately 1 second. at about 40 seconds, more preferably from about 1 second to about 10 seconds, and most preferably from about 1 second to about 2.5 seconds.

Under these conditions, methanol selectivity is in the range of approximately 0.35 to at least 0.60 with lower selectivities for the other alkane-containing feed stream oxygenates. The conversion of methane is approximately 10% and the conversion of the other hydrocarbon components of natural gas is comparable. After the reaction, separation and recycling of unreacted hydrocarbons is performed.

For continuous operation, the fuel (e.g. a C1-C4 alkane or C1-C4 alkanes such as those provided in natural gas) and the oxidizer should be well mixed. For this purpose a mixing chamber / reactor is provided to completely mix the reaction components and also to induce the generation of alkyl free radicals (e.g., without limitation, methyl) which are then contained in the mixing chamber output stream. . In this regard, the mixing chamber thus effectively provides an injectably mixed back-mix reaction chamber (• 'back-mix reaction chamber') in a reactor system which has an injectably mixed back-mix reaction chamber in fluid communication. with a tubular flow reactor to accomplish the full reaction. While not ideally entering a continuously agitated classic tank reactor model or a classic tubular flow reactor model, the injectably mixed backwash reaction chamber has a number of embodiments. indicates an operational character that has more than one continuously stirred tank reactor or an affinity of the CSTR model (additionally denoted as a continuous feed stirred tank reactor or CFSTR; furthermore denoted as a steady state retromix flow reactor). ) instead of an affinity of the tubular flow reactor model or The injectable mixed back-mix reaction chamber has a spacetime, corresponding to a combined feed rate of the alkane-containing feed stream and the oxygen-containing feed stream, from about 0.05 seconds to about 1.5 seconds. (a preferably contemplated spacetime is approximately 0.1 second) so that the feeds can be effectively mixed and so that an initial induction period to generate alkyl free radicals (e.g., without limitation, free radicals can be accommodated before the product stream from the injectably mixed back-mix reaction chamber (methane, oxygen and methyl free radicals) is fed to the tubular flow reactor for an additional reaction in methanol. In a preferred embodiment, the injectably mixed back-mix reaction chamber design allows injectable mixing of C1-C4 alkane and oxygen-containing feed streams to turbulently agitate the streams and to effectively agitate the turbulent reaction chamber. injectably mixed backmix. In this respect, the generation of methyl free radicals is perceived as the first reaction of the kinetic step in the set of reactions of the kinetic step that reach the direct oxygenation of methane in methanol (respective alkylate oxygenate), and the use of Injectably mixed back-mixing reaction before a tubular flow reactor allows a degree of freedom for independent optimization of this methyl free radical induction step. Other free radicals derived from C 2 -C 4 alkanes should generally have a shorter induction period than the methyl free radical under comparable conditions. Subsequent chain branching kinetic subreactions (kinetic subreaction steps) then cover the methyl free radicals and other components of the product chain of the back mix reaction chamber injectably mixed with methanol and other products; These later sub-reactions are best controlled in the environment of the tubular flow reactor that has traditionally received mixed (but unreacted) methane (alkane) and oxygen from previous systems.

The reactor system therefore provides varying degrees of freedom (e.g., without limitation, spacetime, temperature, and injectable reactor mix, as discussed further and subsequently in the present invention) to increase the underreaction (s) of the reactor. initial kinetic series and also to increase, with some independence of conditions, the initial kinetic series sub-reaction (s), the subsequent kinetic series sub-reactions in the total set of sub-reactions which combine to achieve the total direct oxidation reaction of at least one C1-C4 alkane in at least one respective alkylate oxygenate.

With respect to methane in the alkane-containing feed stream, the induction of methyl free radicals in the mixing chamber / reactor (the injectably mixed back-reaction reaction chamber) is a clear departure from previous teachings of documents such as the US Patent. no. 4,982,023 and U.S. Pat. 4,618,732 which, as noted in the Fundamentals, indicate that the feed streams should be mixed only prior to introduction into a reactor.

Reagents are fed into the mixing chamber / reactor (the injectably mixed back-reaction reaction chamber) into separate streams. At the emergence of the injectably mixed back mix reaction chamber, the reagents are then fed to the tubular flow reactor. Mixing should be performed completely to achieve uniform or essentially uniform distribution of reagent concentration in the injectable mixed back-mix reaction chamber product stream. This is necessary to prevent oxidation of the desired products - methanol and other oxygenates. Such oxidation otherwise occurs in regions not completely mixed where there are relatively high concentrations of oxidant, with proportional reduction in product yield. In this regard, the mixing time in the injectably mixed back mix reaction chamber should be relatively short compared to the residence time in a tubular flow reactor. In view of the total preferred residence times for the reactor system as a whole from approximately 1 second to approximately 2.5 seconds, the residence time in the injectably mixed back mix reaction chamber should be at least 0.1 second. In this regard, the actual turbulent gas mixture can be obtained in less than 1 ms. While there are several embodiments to obtain a satisfactory mix, as will be described below, a preferred embodiment for use with shorter residence times essentially uses opposite turbulent jets with a diverter cone that has its side tending toward the apex (end apical) closer to a tubular flow reactor. The purpose of the cone is to minimize the long residence times for sub-portions of the injectably mixed back-reaction reaction chamber contents in view of the high reactivity of alkyl (e.g. methyl) free radicals.

The reactor walls must be inert in the chemical reaction environment. The construction material of the reactor should be steel, preferably stainless steel, to contain the required total pressure. Since a steel surface decreases methanol selectivity, the steel is preferably coated with an inert coating such as Teflon.

or an organic wax. Inserting a Pyrex or quartz jacket into the reactor also provides a relatively inert surface.

A flow limiting deflector is positioned at the outlet of the injectably mixed backmix reaction chamber to increase the pressure drop between the injectably mixed backmix reaction chamber and the tubular flow reactor and thereby achieves a superior swing characteristic. desired residence time (degree of freedom of control) in the injectably mixed back-reaction reaction chamber. In a preferred embodiment, the flow restriction deflector (bulkhead with openings to allow a fluid position) is convenient and axially movable, so that alternative deflector positions can be arranged by customizing the effective spacetime in the reaction chamber. injectable mixed mixture prior to a process run or during a process run. In a preferred embodiment, the flow restriction deflector is in close proximity to a locking member that is convenient and axially movable, so that variable positions of the deflector (bulkhead) can be defined by partially obstructing the openings in the deflector (bulkhead). by customizing the effective space-time in the injectably mixed back-mix reaction chamber prior to a process run or during a process run; This feature provides another degree of freedom for operational control.

Returning now to an overview of the tubular flow reactor, the maximum temperature axial position is completely sensitive to the reactor inlet temperature, total flow rate and reagent composition. Fluctuations in any of these quantities may cause the position of the reactor "hot spot" to move. In an extreme case, the "hot spot" may move out of the reaction vessel and thus adversely affect performance. The tubular flow reactor is therefore preferably equipped in one embodiment with a thermocouple that can be transferred axially (along the general flow axis in the reactor) through a sliding seal. In another embodiment, a plurality of thermocouples arranged to measure the temperature profile of the tubular flow reactor along the flow axis allows temperature monitoring. The thermocouple set monitors the axial distribution of the gas phase temperature in the reactor, and thermocouple measurements are also used for reactor control.

Methanol, formaldehyde and other oxygenates may undergo thermal decomposition at high temperatures of the tubular flow reactor, resulting in product loss. Such decomposition is minimized by cooling the reactor contents to a location immediately downstream of the "hot spot". Since wall cooling is not sufficiently responsive, a preferred embodiment employs the injection of a cold gas through a pipe whose axial position can also be altered by means of a sliding seal. Cold gas is preferably natural gas, but carbon dioxide, nitrogen or another inert substance may also be used.

Figure 12 shows a simplified cross-sectional view 1200 of a reactor system having a injectably mixed back-mix reaction chamber 1202 coupled near the tubular flow reactor 1204, such that a reactor system having a reaction chamber in . injectably mixed backmixing in fluid communication with a tubular flow reactor is provided for one of the processes described in conjunction with Figures 1 to 11. The main chamber and reactor sections of the reactor system are aligned along the geometric axis 1220 with the chamber. injectable mixed back reaction reaction having the shell 1206 (which defines the internal volume 1234 with a cylindrical surface in cooperation with the shield 1232). Tubular flow reactor 1204 has housing 1210 which defines internal volume 124 8 in cooperation with the section of sliding tubular flow reactor 1204 which has housing 1208 and bulkhead 1232. An alkane containing gas supply stream (a first fluid stream) enters through the alkane gas inlet 1222 and similar alkane gas inlets as described. An oxygen-containing gas supply stream (a second fluid stream) enters through the oxygen gas inlet 1224 and the tapered diverter / distributor 1226. The tapered diverter / distributor 1226 has a tapered base (base 1614 of Figure 16) connected to a portion of housing 1206 in an opposite arrangement to bulkhead 1232. An outlet of the back mix reaction chamber is established by bulkhead (deflector) 1232 and position 1270 (with their associated fluid positions shown in more detail in Figures 17A and 17B) and optional locking component 1230. The bulkhead (deflector) 1232 and optional locking component 123 0 (for variable position setting in real-time reactor system operation) have positions such as position .1270 power to product stream from injectably mixed back-reaction reaction chamber 1202 to tubular flow reactor 1204. 0 tubular flow reactor 120 4 thus has a tubular flow reactor inlet in fluid communication through position 1270 with the output of the back mix reaction chamber 1202 in the shield (baffle) .1232 and in the locking component 1230. The alkane gas inlet 1222 (along with similar alkane gas inlets as described) and .1224 oxygen gas inlet with tapered diverter / distributor 1226 and oxygen inlet port 1228 (along with similar alkane gas inlets as described) are configured (positioned and sized with respect to the alkane-containing and oxygen-containing feed stream streams) to turbulently agitate the reaction components within the internal volume 1234 of the injectably mixed back-mix reaction chamber 1202 by the injectable mixing of the alkane-containing gas feed and oxygen-containing gas feed stream.

Tubular flow reactor 1204 has an output of tubular flow reactor 1260, and tubular flow reactor .1204 has a refrigerant gas inlet 1274 disposed between a tubular flow reactor inlet from positions (position 1270) in the bulkhead. 1232 and a tubular flow reactor outlet 1260 for receiving a refrigerant stream (which enters the .123 refrigeration inlet port and then the .1250 refrigerant inlet port before proceeding to the refrigerant inlet). 1274) and thereby cools the tubular flow reactor 1204 with sudden cooling. In this regard, the refrigerant gas inlet 1274 in one embodiment is in an elongated tube (tube 1262) with at least one opening 1274 (see Figures 18A and 18B for cross-sectional details relative to geometry axis 1220) for conducting rough cooling flow in reactor space 1248. Tube 1262 cooperates with guide tube 1 264. In one embodiment, tube 1262 rotates within guide tube 1264 to regulate the amount of rough cooling applied to one position. In an alternate embodiment, tube 1262 is axially slidable (with reference to geometry axis 1220) for positioning within the tubular flow reactor 1204 and for providing local quenching. However, in another embodiment, tube 1262 rotates within guide tube 1264 to regulate the amount of rough cooling applied to one position and is also axially slidable (with reference to geometry axis 1220) for positioning within the tubular flow reactor. 1204 and for the provision of local blast cooling. Suddenly cooled components (including drawing references 1262, 1250, 123 6, 1264 and 1274) thus provide a degree of freedom for temperature profile control along the 1220 geometry axis within the tubular flow reactor 1204 Thermocouples such as thermocouple 1216 and similar thermocouples, as described, offer measurements for the temperature profile in one embodiment. A sliding thermocouple 1214 (with thermocouple sensor 1272 and sealed with sliding seal 1212 to housing 1210) provides temperature profile measurements in another embodiment. Figure 12 shows an embodiment having stationary thermocouples such as thermocouple 1216 as well as a sliding thermocouple 1214 (with thermocouple head 1272).

Tubular flow reactor 1204 has housing 1210 which defines internal volume 1248 in cooperation with the section of sliding tubular flow reactor 1204 which has housing 1208 and which also has bulkhead 1232 (with optional locking component 1230 to provide the position 1270 as a variable position in cross section). The bulkhead 1232 and locking member 1230 are at the slidably sealed interface to the housing of the back mix reaction chamber 1206 and are thus effectively joined to the section of the sliding tubular flow reactor 1204 having the housing 1208. The section housing 1208 is therefore slidably sealed at the interface to housing 1210 and also housing 1206, with seals 1244, 1246 and 1238 providing insulation from the external environment. Injectively mixed back-mix reaction chamber 1202 has an internal volume of the injectably mixed back-mix reaction chamber 1234 defined by reaction chamber housing 1206 and bulkhead 1232 (with optional locking component 1230). The bulkhead 1232 (and locking member 1230) are therefore slidably movable during real-time operation of the sight reactor system 1200 to progress within the back-mix reaction chamber housing 1206 toward inlet 1224 to thereby measurably decreasing internal volume 1234, and bulkhead 1232 (and locking member 1230) are alternately slidably movable during real-time operation to retract away from inlet 1224, thereby commensurately expanding internal volume 1234. In the embodiment of Figure 12, tubular flow reactor 1204 has an internal volume of tubular flow reactor 1248 defined by tubular flow reactor housings 1208 and 1210 and bulkhead 1232 (with locking member 1230). The bulkhead 1232 (and locking member 1230) are therefore slidably movable during the real-time operation of the sight reactor system 1200, thereby dramatically decreasing the internal volume 1248 as it moves away from inlet 1224, and bulkhead 1232 (with optional locking component 1230) are alternately slidably movable during real-time operation to move toward inlet 1224, thereby commensurately expanding internal volume 1248. This movable interface allows a degree of freedom to control the relative spacetime (essentially equivalent for gas flow to the internal reaction volume divided by the volumetric flow rate moving through the internal reaction volume) within the 12 00 view reactor system between a 12 04 tubular flow reactor and injectably mixed back-reaction reaction chamber

1202.

Essentially, the functionality allowed by the characteristics of the bulkhead 1232 (and locking component 1230) is for a backmix reaction chamber where the internal volume (defined by an inner surface of a shell and also by the surface of any component in the sealed interface). movable to that inner surface) can be easily modified so that the spacetime provided by the back mix reaction chamber by chemically reacting the compositional components in the gaseous liquids flowing within the inner volume can be modified without necessarily modifying the (s) flow (s), turbulence, and / or pressure drop of these liquids. In this regard, any approach to modifying the internal volume from a first internal volume to a second internal volume is potentially useful. In a preferred embodiment, for example, the bulkhead 1232 is axially fixed, the tapered diverter / distributor 1226 has a base sufficiently large to slidably seal against the back-mix reaction chamber housing 1206, the tapered diverter / distributor 1226 has a sliding tube (not shown) to interconnect to inlet 1224 and the tapered diverter / distributor 1226 thereby commensurably decreases internal volume 1234 as it moves away from inlet 1224, and commensurably expands internal volume 1234 as it moves toward In another embodiment, the housing 126 has a movable portion that invades the chamber to decrease the internal volume 1234 and is alternatively removed from the chamber to increase the internal volume 1234. However, in another embodiment, a component with diaphragm modifies its characteristics to commensurately modify the internal volume 1234 .

Seal 1246, seal 1212, seal 1244, seal 1238, seal 1242, and seal 1240 allow sliding movement of the moving components of the view 1200 reactor system. Rotating member 1218 allows rotation of the rotating member. 1230 lock during operation. As should be apparent, component movement (especially during operation of the 1200 sight reactor system) is preferably achieved with the aid of variable speed motors, levers, associated gear levers and / or step and associated gear motors. (not shown, but should be apparent to elements of skill in the art).

In operation, an alkane-containing feed stream and an oxygen-containing feed stream are introduced into the injectably mixed back-mix reaction chamber 1202 through the inlet ports such as inlet 1222 (the alkane-containing feed stream) and inlet 1224. (the supply stream containing oxygen). The internal conditions of the injectably mixed back-mix reaction chamber 1202 are controlled to induce the formation of alkyl free radicals in the injectably mixed back-mix reaction chamber 1202 to result in a stream of injectably mixed back-mix reaction chamber product to the outlet. and fluid communication in the tubular flow reactor 1204 through positions such as position 1270 in bulkhead 1232 and blocking member 1230. The components are sized and arranged to provide significant molecular momentum in the incoming liquids so that the injectable mixture and a turbulent reaction fluid are established in the injectably mixed back-mixing reaction chamber 1202. The feed of the product stream from the injectably mixed back-reaction reaction chamber to the tubular flow reactor 1204 through position 127 0 therefore comprises , the oxygen o, unreacted alkane and at least a portion of the alkyl free radicals that have been induced into the injectably mixed back-mix reaction chamber 1202. In this respect, the "reaction" of alkane in alkylate oxygen (focally, the " reaction "from methane to methanol) involves a large plurality of short-term reactions (also referred to in the present invention as kinetic series or kinetic sub-reactions); Of course, there may be at least 60 kinetic series sub-reactions in the total "reaction" of methane to methanol and the other alkylate oxygen occurring in the system. The initial kinetic series sub-reaction occurs to induce an alkyl radical of an alkane when an alkane molecule is exposed to molecular oxygen. This induction of an alkyl radical appears to require a time period of many orders of magnitude longer than the time required to turbulently mix the two fluid feed streams and also appears to be a time-consuming kinetic series sub-reaction. respectively to the kinetic series sub-reactions that occur once the free alkyl radical is available. There is therefore an efficacy in handling this reaction in a separate injectable mixed back-mix reaction chamber which is in fluid communication with the tubular flow reactor where a consistent portion (over time and in steady state operation) of alkyl radicals will essentially be conducted (fed into the tubular flow reactor) to provide the basis for many parallel, subsequent and sequential kinetic series sub-reactions that are highly exothermic and require a heat control approach more receptive to tubular flow reactors than the injectably mixed back reaction chambers. Although coupled close to the tubular flow reactor in embodiments, the injectably mixed back-mix reaction chamber provides the reaction components with an essentially universal compositional and physical operating state (temperature, pressure and molecular momentum) within their spacetime compared to the system. tubular flow; This allows the control of the essential alkyl radical induction step independently of the tubular flow reactor where along the geometrical axis of the tubular flow reactor the reaction components have an axially (and probably radially) differentiated composition and physical state. .

As should be apparent to those skilled in the art, gradation control in a system such as the 1200 view reactor system needs to control the challenge of providing an acceptable molecular momentum in increasing spacetime situations; if the molecular momentum decreases, the reaction fluid in the injectably mixed back-mix reaction chamber will migrate to the laminar flow range and the total required consistency of the reaction fluid from the injectably mixed back-mix reaction chamber may thereby be potentially compromised; therefore, a 1200-view reactor appears effective in small-scale processing to make "stranded gas"

a valuable product.

The total spacetime of the reactor system, corresponding to a combined feed rate of the alkane containing feed stream and the oxygen containing feed stream, is no more than 40 seconds and preferably no more than 2 seconds. ,5 seconds. The reaction time-space for the injectably mixed back-mix reaction chamber is controlled to be no longer than 1.5 seconds.

Figures 13A and 13B show simplified cross-sectional views 1300 and 1350 of the details on modifying the internal volume of the injectably mixed backwash reaction chamber 1202 of Figure 12. In this regard, an alternative view 1300 is presented for the reaction chamber. injectable mixed backmix 1202 in Figure 13A where a "hairbrush" dispenser 1308 (further detailed in Figures 15A and 15B) for the oxygen containing feed stream is illustrated. View 1300 of Figure 13A generally shows a bulkhead 1304 and optional locking member 1302 in fully expanded or extended orientation to housing 1306.

The view 1350 of the reactor of Figure 13B generally shows the bulkhead 1304 and optional locking member 126 in the orientation inserted into the housing 130 to decrease the volume (and, in steady state operation, the spacetime) of the chamber injectable mixed back reaction reaction mixture corresponding to the volume (spacetime) of view 1300.

Figure 14A shows a simplified cross-sectional view 150 of another alternative design for the injectably mixed back-mix reaction chamber 1202 of Figure 12. In this regard, a hemispherical main portion 1402 is profiled to the housing, with a comparably profile hemispheric in the introduced bulkhead.

Figure 14B shows a view 1450 illustrating the injectably mixed back-mix reaction chamber 1202 of Figure 12 with a modified internal volume from that shown in Figure 12. The bulkhead 1232 and the locking component (optional) 1230 are described in the inserted orientation. to housing 1206 to decrease the volume (and, in steady state operation, spacetime) of the injectably mixed back-mix reaction chamber 1202 respective to the volume (spacetime) of view 1200.

Figures 15A and 15B show aligned cross-sectional views 1500 and 1550 of the "hairbrush" fluid application insert 1308 for an alternative design for the injectably mixed back-mixing reaction chamber 1202 of Figure 12. The geometric axis 1504 is aligned with the geometry axis 1220 in the preferred embodiment, with view 1500 showing the respective hairbrush dispenser "130 having a plane perpendicular to the geometry axis 1504, and view 1550 showing details of the hairbrush dispenser" 1308 to a plane parallel to the geometric axis 1504. The oxygen-containing feed stream is fed into the internal flow space 1234 of a plurality of openings (such as the opening 1502) disposed along the geometric axis of the reaction chamber. injectably mixed back-mix on the essential centerline of the cylindrical surface of the housing 1206 and in the orientation not parallel to the geometrical axis. of the injectably mixed back-mix reaction chamber 1220 wherein the geometry axis 1504 is aligned essentially with the geometry axis 1220.

Figure 16 shows a simplified cross-sectional view 1600 of the inner portions for the tapered fluid application recess 1226 for applying the oxygen containing feed stream to the injectably mixed back-mix reaction chamber 1202 of Figure 12. The internal flow diverter is defined by a conical surface 1604 having a geometry axis 1602. A conical base 1614 is at one end of the geometry axis 1602, and the apical end 1612 (an end which, if the cone were extended, would finally converge to provide the apex of the cone) is at the opposite end of the geometric axis 1602. As shown in view 1200 of Figure 12, the geometric axis 1602 is aligned with the geometric axis 1220 of the injectably mixed back-reaction reaction chamber 1202 when the tapered diverter 1226 is disposed within the housing. 1206 so that the output of the back mix reaction chamber (position 1270) is closer to the apical end 1612 than to the conical base 1614. The oxygen-containing feed stream is fed into inlet 1610 (from inlet 1224 of Figure 12) and then into internal flow space 1234 of a plurality of openings 1608 disposed at the along the geometry axis of the injectably mixed back-reaction reaction chamber 1220 (geometry axis 1602) and in orientation non-parallel to the geometry axis 1220. Inner position 1606 fluidly carries the oxygen-containing feed stream to the plurality of openings 1608.

Figures 17A and 17B show simplified cross-sectional views of details of the interface baffle (1232/1230) and the positioning at the interface between the injectably mixed back-mixing reaction chamber 1202 and the tubular flow reactor 1204 of the reactor system of Figure 12. In view 1700 of Figure 17A, bulkhead 1702 has at least one aperture 1704 which defines a position (see position 1270 in Figure 12) for fluid communication of a stream of injectable mixed back-reaction reaction chamber product from the chamber. injectably mixed back reaction reaction 12 02 to the tubular flow reactor 1204. The shield 1702 (shield 1232 in Figure 12) provides the position with at least one aperture 1704 which has a cross-sectional area. When fluid passes, the apertured shield 1702 1704 defines a deflector to create a pressure drop between the injectably blended backwash reaction chamber 12 02 and the tubular flow reactor 1204 as fluid passes from the reaction chamber. injectably retromixed 1202 to tubular flow reactor 1204. In a "fitted" reactor system, apertures 1704 can be precisely sized in one embodiment so that no blocking components are required; Such an arrangement has few degrees of freedom for operation, but is also less complex from a sealing and construction point of view. For real-time operational variation of the effective position created by aperture 1704, a locking member 1230 is arranged in an alternative embodiment where, as shown in view 1750 of Figure 17B, locking member 1230 may be rotated to "lock" a portion of the cross-sectional area of aperture 1704 where a portion of locking member 1706 (locking member 1230 of Figure 12) is shown compressing the position of opening 1704 (note that view 1750 may be conceptualized as a parallel view to the geometric axis 122 0 and toward the injectably mixed backwash reaction chamber 12 02 from the tubular flow reactor 120) and thereby restricting the position.

In a preferred embodiment, the bulkhead (1232/1702) has at least one opening 1704 as a first opening, and the locking member (1230/1706) has at least one second opening (1708). The first and second apertures preferably have substantially identical dimensions, and the first aperture 170 and the second aperture 170 are mutually arranged to align positively at a relative positioning of the bulkhead (1232/1702) and component. (1230/1706), to define position (1270) to have essentially an equivalent of the cross-sectional area to the cross-sectional area of the first aperture. In view 1750, this can be appreciated by considering that the portion of aperture 1704 that is not blocked from use of position by locking member 1706 is also opening portion 1708 that is not blocked from use of position by bulkhead 1702.

An alternative embodiment of the combination of the bulkhead (1232/1702) and the locking member (1230/1706) which does not include the use of the rotation member 1218 is further discussed with respect to Figure 21. In this alternative embodiment, the bulkhead (1232/1706) 1702) is movable respectively to the stationary locking member (1230/1706) where the key locking 1710 provides an axially slidable impediment (with respect to the 1220 geometric axis) against the key 2110 (Figure 21) to prohibit rotation of the locking member (1230/1706). In this embodiment, the shield (1232/1702) is securely attached to the housing 1208, but the housing 1208 additionally rotates about the geometry axis 1220 to achieve a variable position 1270 defined by aperture 1704 and aperture 1708. Key 2110 is affixed to the enclosure. 1206 (details not shown) and aperture 1714 (Figure 17A) provide a non-resistive aperture for key 2110 to pass to internal volume 1248 so that the shield (1232/1702) and locking member (1230/1706) move axially (geometry axis 122 0) respectively to input 1224 with lock member 1230/1706 always contained and bulkhead 1232/1702 always rotating about geometry axis 1220.

Ball bearings 1712 are used in preferred embodiments to increase the smooth rotation of the movable member (of the bulkhead 1232/1702 or locking member 1230/1706, depending on their particular embodiment) against the non-movable member in the deflector system.

Figures 18A and 18B show simplified cross-sectional views 1800, 1850 and 1860 of detail and positioning for the variable position rough cooling inlet 1274 for the reactor system of Figure 12. Guide tube 1264 is shown in perpendicular cross-section. 1800, respectively, to the geometry axis 1220, with the cross-section of tube 1802 having an elongate groove 1808 following along the axis 1220. The elongate groove is difficult to be shown in Figure 12, but is described in Figures 18A and 18B as fully open position 1808 to drive axial locking; rough cooling tube 1804/1262 is shown with opening 1806/1274 - see inlet position 1274 in Figure 12 - to show that it is an opening having a substantially less axial dimension than the axial dimension of fitting 1808 of guide 1802/1264. The tube 1804/1262 cooperates with the guide tube 1802/1264 as shown in view 1850 so as not to conduct abrupt cooling to internal volume 1248 when opening 1806 is rotated to obstruct position (1274) with the inner surface of the guide tube. 1802/1264. In one embodiment, tube 1804/1262 is axially slidable within guide tube 1802/1264 to axially reposition opening 1806/1274 along geometry axis 1220. View 1860 then shows the radial alignment rotation between tube 1804/1262. and guide tube 1802/1264 so that position / input 1274 is activated. It should be noted that several alternative assemblies (not shown) of apertures 1806 can easily be provided at different radial positions of tube 1804 to provide alternative rough cooling models as a function of tube radial orientation 1804/1262 along geometry axis 1220. in tubular flow reactor 1204.

Figures 19A through 19C show a series of temperature profiles for a tubular flow reactor of the reactor system of Figure 12 in operation. In this regard, the abscissa axis 1904 and the ordinate axis 1906 are identical in all Figures 19A, 19B and 19C, with the abscissa axis 1904 showing the distance along the geometric axis .122 of the tubular flow reactor. 12 04 and the ordinate axis .1906 illustrates the temperature within the reaction fluid of the tubular flow reactor 1204. The locus 1902 (Figure 19A) is a conceptualized description of a temperature profile for the tubular flow reactor 1204 without the benefit. of sudden cooling. Locus 1922 (Figure 19B) is a conceptualized representation of a temperature profile for tubular flow reactor 1204 with the benefit of blunt cooling from position 1938 essentially at outlet 1260. Locus 1932 (Figure 19B) is a conceptualized representation of a temperature profile for the 1204 tubular flow reactor with the benefit of quenching only at position 1938. The kinetics series sub-reactions discussed above will vary in their activity depending on the temperature profile along the 1220 geometry axis within the Thus, for example, the product mixture of the 1204 tubular flow reactor will be different for each of Loci 1902, 1922, and 1932 by its differentiated thermal profiles, commensurately differentiated energies, and commensurately differentiated kinetic activity for subreactions. in the set of kinetic series subreactions. The quench-cooled pipe design therefore offers yet another degree of freedom for optimizing the composition of an alkyl oxygen reactor system product stream generated from a C1-C4 alkane-containing feed stream and a stream. feed containing oxygen.

Figure 20 shows a simplified cross-sectional view 2000 of an alternative embodiment of a reactor system having an injectably mixed back-mix reaction chamber coupled to a tubular flow reactor. The interface baffle assembly (bulkhead 1232 and locking member 1230 of the embodiments of the assembly as described with respect to Figure 12 and the alternate key arrangement embodiments of Figures 17A, 17B and 21) is slidable and rotatable during real-time operation of the vista 2000 reactor system to progress and / or retract away from inlet 2062 by using a threaded seal and connection facilitated by male threading 2012 (male threading 2212 in Figures 21 and 22A to 22C ). Most of the injectably mixed backmix reaction chamber and tubular flow reactor share housing 2070, which is additionally threaded to provide female threading to cooperate with 2012/2212 threading. Figures 22A-22C show further detail in this regard, where Figure 22A shows a tubular flow reactor liner 2016 in the fully progressed position, Figure 22B shows a tubular flow reactor liner 2016 in the forward / retract position. midpoint and Figure 22C shows the tubular flow reactor jacket 2016 in the fully retracted position.

The back-mix reaction chamber and a tubular flow reactor of the Vista 2000 reactor system are aligned along the 2014 geometric axis. An alkane-containing gas feed stream (a first fluid stream) enters through the feed gas inlet. 2060 and the plurality of openings of the alkane gas inlet as described. An oxygen containing gas feed stream (a second fluid stream) enters through the oxygen gas inlet 2062 and the hairbrush dispenser as previously discussed with respect to Figures 15A and 15B. In an alternative embodiment, a tapered diverter / distributor (Figure 16) is used for the oxygen containing feed stream.

The tubular flow reactor has a tubular flow reactor liner 2016 at the slidably sealed interface on seal 2008 to housing 2004 and provides a fluid outlet in a relatively small space defined by housing 2004. housing 2004 has sufficient axial depth to accommodate the complete axial crossover driven by 2012/2212 threading (see also Figures 22A-22C). Casing 2004 has an output to the reactor product stream at output 2020. The refrigerant gas inlet 2002 receives the refrigerant gas stream described above in the refrigerant gas space 2072 (defined between the inner surface of the casing 2070 and the outer surfaces of the shirt 2016 and the lock tube 2006). The refrigerant gas stream then proceeds into the inner space of the liner 2016 through the spiral fitting 2018 at a point where an axial fitting (the axial fitting 2032 of the perpendicular cross-sectional view 2028 through the geometry axis 2014 in the right-facing orientation in 2042 and Figure 23) of the locking tube 2006 and spiral fitting .2018 is aligned to define a position (2302 of Figure 23) and also to thereby coarsely cool the inner space of the tubular flow reactor jacket 2016. The shirt 2016 therefore cooperates near the lock tube .2006.

The jacket 2016 is sealed to the housing 2070 with a sliding seal 2074 and thereby rotates to simultaneously proceed / regress respectively to the injectably mixed back-mixing reaction chamber by means of lines 2012/2212 (Figures 22A-22C), regulating the amount of rough cooling applied to a position within a tubular flow reactor jacket 2016 (described with Figure 20 and further described with Figure 23) and modifying the cross-sectional area of the position (fixed switch deflector assembly as discussed previously and further discussed in Figure 21). Although these three degrees of control freedom (the deflector's position progression / regression, the application of blunt cooling and the cross-sectional area of the deflector position) are therefore not independently controlled, differences in the rate of change of each One with a sleeve rotation 2016 allows a controllable system that has fewer seals than the embodiment described with respect to Figure 12 and only with very limited convolution between these three degrees of freedom for normal operation. In this regard, a full rotation of the liner 2016 achieves a complete transfer of position of the spiral fitting 2018 (its full axial analog range), perhaps approximately 2% of the full axial analog range for positional deflector progression / regression and 600% of the full axial analog range of cross-sectional area of position for a deflector having six openings (Figures 17A and 17B). Therefore, the liner 2016 is first rotated to the position within the axial analog range for positional progression / regression of the deflector, then positioned within the axial analog range for abrupt cooling, and finally to position itself within the axial analog range for the deflector. cross-sectional area of position. Since deflector positioning is predicted to be a relatively strategic operating adjustment for a particular alkane gas feed stream composition, real-time operating adjustments should be more closely related to single rotation (1/6 rotation) quenching. ) to position the deflector position.

The perpendicular cross-sectional view 2030 through the geometric axis 2014 in the left-facing orientation in 2040 shows additional detail in the positioning of the opening to insert feeds from input 2060 and 2062 in the back mix reaction chamber.

Figure 21 shows details of the shield / baffle 2100 for the embodiment of the reactor system of Figure 20 and also for the alternative embodiment of the interface between the injectably mixed backmix reaction chamber and a tubular flow reactor of the embodiment of the reactor system. Figure 12 as previously noted with respect to Figures 17A and 17B. The shirt 2016 is repeated in Figure 20 with male thread 2012/2212. As described for the respective alternative embodiment to Figures 17A and 17B, locking member 2108 is contained by rotation by key 2110 (as inserted into socket 1710 - Figure 17B) and bulkhead 2104 is in a non-slip attachment to jacket 2016. Ball bearings 2106 are in contact with shield 2104 (sleeve end 2016) to locking member 2108. Shield 2104 (sleeve 2016) rotates freely around key 2110 due to uncontained circular opening 1714 (Figure 17A) . As previously discussed, Figures 22A-22C show details of axial positioning 2200, 2230, and 2260 for the interface between the injectably mixed back-mix reaction chamber and the tubular flow reactor of the embodiment of the reactor system of Figure 20. The jacket 2016 is reprized in Figure 20 with male thread 2012/2212.

Figure 23 shows an additional detail 2300 in the blast cooling inlet for the embodiment of the reactor system of Figure 20. In this regard, a vertical view of the liner 2016 and a lock tube 2006 in alignment with the inlet shaft are shown. for input 2 0 02 (Figure 20). Jacket 2016, lock tube 2006, spiral fitting 2018 and axial fitting 2032 (view 2028 of Figure 20) are all repeated in Figure 20. Position 2302 shows the alignment point of lock tube 2006 and spiral fitting 2018 for the application of quench cooling gas to the 2016 jacket to thereby quench cooling the inner space of the tubular flow reactor.

Figures 24A and 24B show details of the axial view for the embodiment of the reactor system of Figure 20. Figure 24A shows a right-facing view along the geometric axis 2014 (Figure 20) of the outside of the reactor system; inlets 2060 and 2062 are reprized in Figure 20. Figure 24B shows the cross-sectional view 2450 through geometry 2014 in the left-facing orientation in 2022 (Figure 20); input 2002 is reprized in Figure 20 and apertures 1704/1706 are reprized in Figures 17A and 17B.

Figures 25A and 25B show views 2500 and 2550 of two embodiments of the tubular flow reactor system having injectably mixed inlet zones (zone 2520 in both Figures 25A and Β), blunt cooling and temperature sensing. in multiple positions. Mixing zone 2520 in Figure 25A and Figure 25B shows a full cone symbolic tapered diverter 2502, highly similar to the tapered diverter of Figure 16 and also Figure 12. The system view 2500 of Figure 25A shows multiple thermocouples ( such as thermocouple 2510) and multiple coarse-cooled inlet ports (such as coarse-cooled inlet port 25 08) in housing 2512. System view 2550 of Figure 25B shows a variable thermocouple 2504 and a door-to-door seal. quench cooling input of variable position thermocouple 2506 disposed within the internal space defined by enclosure 2514. The quench cooling and temperature measurement is therefore highly similar in Figure 12 and Figure 25B for the tubular flow reactors of both the achievements. The systems of Figure 25A and Figure 25B are useful for providing reactor systems that are highly similar to the embodiments of Figures 12 and 20, except for the absence in Figures 25A and 25B of a separation deflector assembly defining a transparent interface. between an injectably mixed backmix reaction chamber and the tubular reactor. In this regard, the operation data of a system of Figure 25A or Figure 25B, when compared to the operation data of a system of Figure 12 or Figure 20, have value in indicating the effectiveness of the respective deflector interface adjustments. (bulkhead 1232 / component 1230 in Figure 12 or the threaded deflector assembly of Figure 20).

It should be understood that each of the elements described above or two or more together may also find a useful application in other types of methods and constructions, which differ from the types described above. Although the invention has been illustrated and described as embodied in the method and apparatus for methanol production, it should not be limited to the details shown, since various modifications and structural changes can be made without deviating in any way from the character. of the present invention.

Without further analysis, the foregoing account will thus fully disclose the main point of the present invention that others can readily adapt by applying current knowledge to various applications without omitting features which, from a prior art point of view, constitute reasonably essential features of the generic or specific aspects of the present invention. What is claimed as new and which should be protected by the Charter is indicated in the appended claims.

Claims (16)

1. METHOD FOR. MANUFACTURING AT LEAST ONE OXYGENATED ALKILY THROUGH THE ALKAN PARTIAL OXIDATION REACTION OF AN ALCAN AND OXYGEN POWER SUPPLY GAS CURRENT AND A OXYGEN CONTAINING GAS POWER CURRENT: The method is said to comprise: a reactor system having an injection back-mix reaction chamber in fluid communication with a tubular flow reactor; feeding said alkane-containing feed stream and said oxygen-containing feed stream to said injection back-mix reaction chamber; the induction of alkyl free radical formation in said injection backmix reaction chamber to obtain a product stream from the injection backmix reaction chamber comprising oxygen, said alkane, and at least a portion of said free radicals of alkyl; feeding said product stream from the back mixing reaction chamber by injection into a tubular flow reactor; and reacting said product stream from the injection back-mix reaction chamber to said oxygenated alkyl in said tubular flow reactor; wherein said alkane is selected from the group consisting of methane, ethane, propane and butane. Method according to claim 1, characterized in that said feed of said alkane-containing feed stream and said oxygen-containing feed stream by injection to said alkane-containing feed stream and said feed stream containing oxygen to thereby turbulently agitate the fluid within said injection back-mix reaction chamber. Method according to claim 1, characterized in that said alkane comprises methane and said oxygenated alkyl comprises methanol. Method according to Claim 3, characterized in that said oxygenated alkyl further comprises formaldehyde. Method according to claim 1, characterized in that said oxygenated alkyl comprises ethanol. Method according to claim 1, characterized in that said feed of said product stream from the injection back-mixing reaction chamber fluidly transports said product stream from the back-mixing reaction chamber through a feed. flow restriction deflector. Method according to claim 1, characterized in that said reactor system has a time period for said induction and said reaction, corresponding to a combined feed rate of said alkane-containing feed stream. said oxygen-containing supply stream of no more than 40 seconds. A method according to claim 1, characterized in that said tubular flow reactor has a tubular flow reactor inlet and a tubular flow reactor outlet, and said method further comprises temperament cooling of the said tubular flow reactor with a refrigerant stream received from a refrigerant gas inlet disposed at a first physical location between said tubular flow reactor inlet and said tubular flow reactor outlet. Method according to claim 8, characterized in that said cooling is obtained by axially adjusting the first physical location to a second physical location. A method according to claim 1, characterized in that said tubular flow reactor discharges a reaction product stream from said tubular flow reactor outlet, and said alkane comprises methane, and a first alkyl. The oxygenated form comprises methanol, and said method further comprises purifying said reaction product stream with a liquid absorber to condense methanol from said reaction stream. Method according to claim 10, characterized in that, in said purification, said absorber also absorbs carbon dioxide from said reaction product stream. A method according to claim 10, characterized in that a second oxygenated alkyl comprises formaldehyde, and said absorber additionally absorbs formaldehyde from said reaction product stream in said purification. A method according to claim 10, characterized in that said scrubbing is obtained with a scrubber, and said method further comprises recycling a recycle stream from said scrubber to said alkane-containing feed stream. Method according to claim 13, characterized in that said recycling stream provides a weight percentage ratio of from about -4: 5 to about 20:21 of alkane in said alkane-containing feed stream. Method according to Claim 1, characterized in that said injection back-mixing chamber has a back-mixing reaction chamber housing and a bulkhead in a slidably sealed interface with said reaction chamber housing. said injection retromix reaction chamber has an internal volume of the injection retromix reaction chamber defined by said backmix reaction chamber enclosure and said bulkhead, said retromix reaction chamber enclosure. has a portion of the casing in an opposite arrangement to said bulkhead; and said induction further comprises sliding displacement of said bulkhead during real-time operation of said reactor system to progress within said housing of the injection back-reaction reaction chamber to said portion of the housing, thereby commensurately decreasing. the internal volume of said injection back-mix reaction chamber, and alternatively the sliding displacement of said bulkhead during real-time operation of said reactor system within said injection-back reaction chamber housing to retract retracting said said of the housing to thereby commensurably expand the internal volume of said injection back-mix reaction chamber. Method according to claim 1, characterized in that said feeding of said alkane-containing feed stream further comprises pressurizing said alkane-containing gas feed stream with a centrifugal blower prior to entering said chamber. injection backmixing.