WO2005035689B1 - Process for the conversion of natural gas to hydrocarbon liquids - Google Patents
Process for the conversion of natural gas to hydrocarbon liquidsInfo
- Publication number
- WO2005035689B1 WO2005035689B1 PCT/US2004/015292 US2004015292W WO2005035689B1 WO 2005035689 B1 WO2005035689 B1 WO 2005035689B1 US 2004015292 W US2004015292 W US 2004015292W WO 2005035689 B1 WO2005035689 B1 WO 2005035689B1
- Authority
- WO
- WIPO (PCT)
- Prior art keywords
- stream
- hydrogen
- reactive
- reactor
- natural gas
- Prior art date
Links
- 150000002430 hydrocarbons Chemical class 0.000 title claims abstract 40
- 239000004215 Carbon black (E152) Substances 0.000 title claims abstract 39
- 239000003345 natural gas Substances 0.000 title claims abstract 28
- 239000007788 liquid Substances 0.000 title claims abstract 27
- 238000000034 method Methods 0.000 title claims abstract 15
- 238000006243 chemical reaction Methods 0.000 title claims 7
- 239000001257 hydrogen Substances 0.000 claims abstract 31
- 229910052739 hydrogen Inorganic materials 0.000 claims abstract 31
- 239000007789 gas Substances 0.000 claims abstract 29
- UFHFLCQGNIYNRP-UHFFFAOYSA-N hydrogen Chemical compound [H][H] UFHFLCQGNIYNRP-UHFFFAOYSA-N 0.000 claims abstract 29
- 125000002534 ethynyl group Chemical group [H]C#C* 0.000 claims abstract 21
- 239000005977 Ethylene Substances 0.000 claims abstract 15
- VGGSQFUCUMXWEO-UHFFFAOYSA-N ethene Chemical compound C=C VGGSQFUCUMXWEO-UHFFFAOYSA-N 0.000 claims abstract 15
- 230000003197 catalytic Effects 0.000 claims abstract 11
- 238000002485 combustion reaction Methods 0.000 claims abstract 7
- 238000010438 heat treatment Methods 0.000 claims abstract 3
- 239000000047 product Substances 0.000 claims 46
- 238000005984 hydrogenation reaction Methods 0.000 claims 16
- 239000001301 oxygen Substances 0.000 claims 14
- 229910052760 oxygen Inorganic materials 0.000 claims 14
- MYMOFIZGZYHOMD-UHFFFAOYSA-N oxygen Chemical compound O=O MYMOFIZGZYHOMD-UHFFFAOYSA-N 0.000 claims 14
- 239000000446 fuel Substances 0.000 claims 12
- CURLTUGMZLYLDI-UHFFFAOYSA-N carbon dioxide Chemical compound O=C=O CURLTUGMZLYLDI-UHFFFAOYSA-N 0.000 claims 11
- 229910002092 carbon dioxide Inorganic materials 0.000 claims 11
- 239000001569 carbon dioxide Substances 0.000 claims 11
- 239000007800 oxidant agent Substances 0.000 claims 8
- 230000001590 oxidative Effects 0.000 claims 8
- 230000005611 electricity Effects 0.000 claims 6
- 238000010791 quenching Methods 0.000 claims 6
- 238000002156 mixing Methods 0.000 claims 5
- 230000000171 quenching Effects 0.000 claims 5
- 229940117927 Ethylene Oxide Drugs 0.000 claims 4
- IAYPIBMASNFSPL-UHFFFAOYSA-N oxane Chemical compound C1CO1 IAYPIBMASNFSPL-UHFFFAOYSA-N 0.000 claims 4
- 239000000463 material Substances 0.000 claims 3
- 230000003134 recirculating Effects 0.000 claims 3
- 150000002431 hydrogen Chemical class 0.000 claims 2
- 239000012263 liquid product Substances 0.000 claims 2
- 230000001737 promoting Effects 0.000 claims 2
- 238000004064 recycling Methods 0.000 claims 2
- 239000003570 air Substances 0.000 claims 1
- 239000006227 byproduct Substances 0.000 claims 1
- UGFAIRIUMAVXCW-UHFFFAOYSA-N carbon monoxide Chemical compound [O+]#[C-] UGFAIRIUMAVXCW-UHFFFAOYSA-N 0.000 claims 1
- 229910002091 carbon monoxide Inorganic materials 0.000 claims 1
- 238000010891 electric arc Methods 0.000 claims 1
- 238000010248 power generation Methods 0.000 claims 1
- -1 syngas Substances 0.000 claims 1
- 230000002378 acidificating Effects 0.000 abstract 1
- 239000003054 catalyst Substances 0.000 abstract 1
- 230000035484 reaction time Effects 0.000 abstract 1
- 239000000126 substance Substances 0.000 abstract 1
Abstract
A process for converting natural gas to liquid hydrocarbons comprising heating the gas through a selected range of temperature for sufficient time and/or combustion of the gas at a sufficient temperature and under suitable conditions for a reaction time sufficient to convert a portion of the gas stream to reactive hydrocarbon products, primarily ethylene or acetylene. The gas containing acetylene may be separated such that acetylene is converted to ethylene. The ethylene product(s) may be reacted in the presence of an acidic catalyst to produce a liquid, a portion of which will be predominantly naphtha or gasoline. A portion of the incoming natural gas or hydrogen produced in the process may be used to heat the remainder of the natural gas to the selected range of temperature. Reactive gas components are used in a catalytic liquefaction step and/or for alternate chemical processing.
Claims
AMENDED CLAIMS received by the International Bureau on 29 November 2005 (29.11.2005) original claims 1-276, replaced by amended claims 1-32 (7 pages).
1. A method for converting natural gas to hydrocarbon liquids, comprising: converting at least a portion of the natural gas to reactive hydrocarbon products, by heating the natural gas in a conversion reactor, comprising a reaction section operated at conversion promoting conditions, such that the reactive hydrocarbon products, comprising acetylene, are produced, converting at least a portion of the reactive hydrocarbon products to hydrocarbon liquids, by reacting a liquefaction feed comprising at least a portion of the reactive hydrocarbon products in a catalytic liquefaction reactor operated at liquefaction promoting conditions, such that the hydrocarbon liquids, comprising naphtha, are produced.
2. The method of claim 15 further comprising quenching the reactive hydrocarbon products.
3. The method of claim 2, further comprising: preparing the acetylene rich liquefaction feed from the quenched hydrocarbon products by intermediate processing, comprising separating at least one effluent stream comprising a non- acetylene component selected from the group consisting of carbon dioxide, hydrogen, carbon monoxide, light gases, syngas, ethylene, and combinations thereof, from the quenched hydrocarbon products.
4. The method of claim 3 wherein the intermediate processing further comprises: separating a light gas rich stream from the quenched hydrocarbon products, hydrogenating the acetylene rich liquefaction feed.
5. The method of claim 3 wherein at least one effluent stream comprises hydrogen, and further comprising: conveying the effluent stream comprising hydrogen to an electrical power generation device, generating electrical power from the hydrogen and an oxygen containing stream, heating the at least a portion of the natural gas that is converted to the reactive hydrocarbon products with the generated electrical power.
6. The method of claim 3 further comprising recycling at least one effluent stream from the intermediate processing to the conversion reactor.
7. The method of claim 6 wherein the at least a portion of the natural gas that is converted to the reactive hydrocarbon products is heated by products of combustion of a second portion of natural gas with an oxidant.
8. The method of claim 6 further comprising: separating a product stream from the catalytic liquefaction reactor into a liquid product stream comprising the hydrocarbon liquids and a gas stream; recycling the gas stream to the conversion reactor;
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recovering the liquid product stream.
92. The method of claim 3. wherein the intermediate processing comprises separating a carbon dioxide rich effluent stream from the quenched hydrocarbon products.
10. The method of claim 9 wherein the intermediate processing further comprises separating a hydrogen rich effluent stream from the quenched hydrocarbon products.
11. The method of claim 9 wherein the intermediate processing further comprises separating a syngas rich effluent stream from the quenched hydrocarbon products.
12. The method of claim 9 wherein the intermediate processing further comprises: separating a light gas rich stream from the quenched hydrocarbon products, hydrogenating the acetylene rich liquefaction feed.
13. The method of claim 12 wherein the intermediate processing further comprises separating a hydrogen rich stream from the quenched hydrocarbon products.
147. A method for converting natural gas to hydrocarbon liquids, comprising: providing a natural gas stream; providing a feed stream comprising all or part of the natural gas stream; providing a burn stream comprising combustible material; conveying the feed stream and the burn stream to a reactor, wherein the burn stream is combusted with an oxidant, and the feed stream is heated by intimate mixing with the combustion products, to a sufficient temperature and for a sufficient time that a product stream comprising reactive products and hydrogen is formed; quenching the product stream; passing at least a portion of the product stream to a catalytic liquefaction reactor; producing the hydrocarbon liquids in the catalytic liquefaction reactor.
15. The method of claim 14 wherein the oxidant comprises oxygen and is supplied from a source selected from the group consisting of oxygen, purified oxygen, air, and oxygen-enriched air.
16. The method of claim 14, further comprising: separating the hydrogen from the hydrocarbon liquids; providing oxygen to fuel a cell or turbine; and reacting the hydrogen with the oxygen in the fuel cell or burning the hydrogen with the oxygen in the turbine to produce electricity.
17. The method of claim 14, further comprising: separating a liquid stream from the hydrocarbon liquids; using at least a portion of the liquid stream to at least partially quench the product stream comprising reactive products.
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18. The method of claim 14, further comprising: segregating of portion of the natural gas stream to form an electrical generation stream; conveying the electrical generation stream to a fuel cell or turbine; providing oxygen to the fuel cell or turbine; reacting the electrical generation stream with the oxygen in the fuel cell or the turbine to generate electricity.
19. A method for converting natural gas to hydrocarbon liquid, comprising: providing a natural gas stream; providing a feed stream comprising all or part of the natural gas stream; providing a burn stream comprising combustible material; conveying the feed stream and burn stream to a reactor wherein the burn stream is burned in a combustion section with an oxidant to heat the feed stream by intimate mixing with the combustion products to a temperature and for a time such that a reactive product stream comprising hydrogen and reactive products is formed, said reactive products comprising acetylene; quenching the reactive product stream; separating from the reactive product stream an acetylene rich stream and a light gas stream; conveying the acetylene rich stream to a hydrogenation reactor; reacting acetylene and hydrogen in the hydrogenation reactor to form ethylene; conveying a portion of the hydrogenation reactor effluent comprising ethylene to a catalytic liquefaction reactor and operating the catalytic liquefaction reactor such that some hydrocarbon liquid is produced; and conveying the hydrocarbon liquid to storage or transport.
20. The method of claim 19 wherein one, some, or all of the natural gas, feed, burn, and oxidant streams is or are preheated using a device selected from the group consisting of electric arc, resistance heater, plasma generator, fuel cell, combustion heater, heat exchanger, and combinations thereof.
21. The method of claim 19, further comprising separating hydrogen from the process and using a portion of the hydrogen for one or more purposes selected from the group consisting of: recirculating back to the reactor; conveying to the hydrogenation reactor; generating electricity directly or indirectly; burning as fuel; and exporting from the process for external use.
60
22. The method of claim 19, further comprising separating hydrogen from one or more sources within the process selected from the group consisting of: a portion of the reactive product stream; a portion of the light gas stream; a portion of the light gas stream after some ethylene has been removed; a portion of the light gas stream after some carbon dioxide has been removed; a portion of the light gas stream after some ethylene and carbon dioxide have been removed; a portion of the hydrogenation reactor effluent; and the hydrocarbon liquid.
23. A method for converting natural gas to hydrocarbon liquids, comprising: providing a natural gas stream; conveying the natural gas stream to a reactor wherein the natural gas stream is partially burned with an oxidant such that a portion of the natural gas stream is heated to a temperature sufficient to convert some of the natural gas to form a reactive product stream comprising hydrogen and reactive products comprising acetylene; quenching the reactive product stream; separating from the reactive product stream an acetylene rich stream and a light gas stream; conveying the acetylene rich stream to a hydrogenation reactor; reacting at least a portion of the acetylene rich stream with hydrogen in the hydrogenation reactor to form ethylene; conveying a portion of the effluent from the hydrogenation reactor to a catalytic liquefaction reactor and operating the catalytic liquefaction reactor such that hydrocarbon liquids are formed; and conveying the hydrocarbon liquids to storage or transport.
24. The method of claim 23, further comprising: separating a portion of the hydrogen from a portion of the light gas stream; conveying a portion of the hydrogen to a fuel cell or turbine; providing oxygen to the fuel cell or turbine; reacting the hydrogen with the oxygen in the fuel cell or burning the hydrogen with the oxygen in the turbine to produce electricity.
25. The method of claim 23 wherein the hydrocarbon liquid comprises naphtha or gasoline.
26. The method of claim 23, further comprising separating hydrogen from the process and using a portion of the hydrogen for one or more purposes selected from the group consisting of:
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recirculating back to the reactor; conveying to the hydrogenation reactor; generating electricity directly or indirectly; burning as fuel; blending with other process streams; and exporting from the process for external use.
27. The method of claim 23, further comprising separating hydrogen from one or more sources within the process selected from the group consisting of: a portion of the reactive product stream; a portion of the light gas stream; a portion of a syngas stream; a portion of the light gas stream after some ethylene has been removed; a portion of the syngas stream after some ethylene has been removed; a portion of the light gas stream after some carbon dioxide has been removed; a portion of the syngas stream after some carbon dioxide has been removed; a portion of the light gas stream after some ethylene and carbon dioxide have been removed; a portion of the syngas stream after some ethylene and carbon dioxide have been removed; • a portion of the hydrogenation reactor effluent; and the hydrocarbon liquid.
28. A method for converting natural gas to hydrocarbon liquids, comprising: providing a natural gas stream; providing a feed stream comprising all or part of the natural gas stream; conveying a burn stream comprising combustible material to a furnace wherein the bum stream is burned with an oxidant comprising oxygen; conveying the feed stream to a reactor wherein the feed stream is heated by indirect heat transfer with the combustion products of the burn stream and oxidant to a temperature and for a time sufficient to form a reactive product stream comprising acetylene and hydrogen; quenching the reactive product stream; separating from the reactive product stream an acetylene rich stream and a light gas stream; conveying the acetylene rich stream to a hydrogenation reactor; reacting acetylene and hydrogen in the hydrogenation reactor to form ethylene; conveying a portion of the hydrogenation reactor effluent comprising ethylene to a catalytic liquefaction reactor and operating the catalytic liquefaction reactor such that hydrocarbon liquids are produced;
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conveying the hydrocarbon liquids to storage or transport.
29. The method of claim 28, further comprising: providing a second feed stream comprising a portion of the natural gas stream, a portion of a stream separated from the process, or both; conveying the second feed stream to a reaction section of the reactor wherein the second feed stream is heated by intimate mixing with the feed stream to a temperature and for a time sufficient such that reactive products comprising acetylene, ethylene, or both, are produced; wherein the feed stream is heated and not reacted, partially reacted, or completely reacted prior to mixing with the second feed stream; and wherein the reactive products produced from the second feed stream are mixed with the reactive products produced from the feed stream to form an improved reactive product stream.
30, The method of claim 28, further comprising separating carbon dioxide from one or more sources within the process selected from the group consisting of: a portion of the reactive product stream; a portion of the light gas stream; a portion of the light gas stream after some ethylene has been removed; a portion of the light gas stream after some hydrogen has been removed; a portion of the hydrogenation reactor effluent; and the hydrocarbon liquids.
31. The method of claim 28, further comprising separating hydrogen from the process and using a portion of the hydrogen for one or more purposes selected from the group consisting of: recirculating back to the reactor; conveying to the hydrogenation reactor; generating electricity directly or indirectly; burning as fuel; and exporting from the process for external use.
32, The method of claim 28, further comprising separating hydrogen from one or more sources within the process selected from the group consisting of: a portion of the reactive product stream; a portion of the improved reactive product stream; a portion of the light gas stream; a portion of the light gas stream after some ethylene has been removed; a portion of the light gas stream after some carbon dioxide has been removed; a portion of the light gas stream after some ethylene and carbon dioxide have been removed;
a portion of the hydrogenation reactor effluent; and a portion of the hydrocarbon liquids.
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Priority Applications (1)
| Application Number | Priority Date | Filing Date | Title |
|---|---|---|---|
| EP04817184A EP1667949A4 (en) | 2003-09-23 | 2004-05-14 | Process for the conversion of natural gas to hydrocarbon liquids |
Applications Claiming Priority (4)
| Application Number | Priority Date | Filing Date | Title |
|---|---|---|---|
| US50520403P | 2003-09-23 | 2003-09-23 | |
| US60/505,204 | 2003-09-23 | ||
| US10/844,852 | 2004-05-13 | ||
| US10/844,852 US7183451B2 (en) | 2003-09-23 | 2004-05-13 | Process for the conversion of natural gas to hydrocarbon liquids |
Publications (3)
| Publication Number | Publication Date |
|---|---|
| WO2005035689A2 WO2005035689A2 (en) | 2005-04-21 |
| WO2005035689A3 WO2005035689A3 (en) | 2005-12-29 |
| WO2005035689B1 true WO2005035689B1 (en) | 2006-02-16 |
Family
ID=34316755
Family Applications (1)
| Application Number | Title | Priority Date | Filing Date |
|---|---|---|---|
| PCT/US2004/015292 WO2005035689A2 (en) | 2003-09-23 | 2004-05-14 | Process for the conversion of natural gas to hydrocarbon liquids |
Country Status (3)
| Country | Link |
|---|---|
| US (8) | US7183451B2 (en) |
| EP (1) | EP1667949A4 (en) |
| WO (1) | WO2005035689A2 (en) |
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2004
- 2004-05-13 US US10/844,852 patent/US7183451B2/en not_active Expired - Lifetime
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2007
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2010
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- 2010-01-08 US US12/684,373 patent/US7915463B2/en not_active Expired - Fee Related
- 2010-01-08 US US12/684,221 patent/US7915462B2/en not_active Expired - Fee Related
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