WO2007133310A2 - Procédé d'oxygénation directe d'alcanes gazeux - Google Patents

Procédé d'oxygénation directe d'alcanes gazeux Download PDF

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Publication number
WO2007133310A2
WO2007133310A2 PCT/US2007/004297 US2007004297W WO2007133310A2 WO 2007133310 A2 WO2007133310 A2 WO 2007133310A2 US 2007004297 W US2007004297 W US 2007004297W WO 2007133310 A2 WO2007133310 A2 WO 2007133310A2
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WIPO (PCT)
Prior art keywords
reaction chamber
injectively
tubular
stream
alkane
Prior art date
Application number
PCT/US2007/004297
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English (en)
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WO2007133310A3 (fr
Inventor
Nathan A. Pawlak
Robert W. Carr
Roger J. Grunch
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Gas Technologies Llc
Priority date (The priority date is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the date listed.)
Filing date
Publication date
Priority claimed from US11/432,692 external-priority patent/US8293186B2/en
Priority claimed from US11/446,371 external-priority patent/US9180426B2/en
Priority claimed from US11/526,824 external-priority patent/US7910787B2/en
Priority to CN200780017054.7A priority Critical patent/CN101443299B/zh
Priority to MX2008014389A priority patent/MX2008014389A/es
Priority to BRPI0710431-6A priority patent/BRPI0710431A2/pt
Application filed by Gas Technologies Llc filed Critical Gas Technologies Llc
Priority to US11/685,852 priority patent/US7578981B2/en
Priority to US11/685,867 priority patent/US7456327B2/en
Publication of WO2007133310A2 publication Critical patent/WO2007133310A2/fr
Publication of WO2007133310A3 publication Critical patent/WO2007133310A3/fr
Priority to US12/273,213 priority patent/US7687669B2/en
Priority to US13/017,169 priority patent/US8524175B2/en

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    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B01—PHYSICAL OR CHEMICAL PROCESSES OR APPARATUS IN GENERAL
    • B01J—CHEMICAL OR PHYSICAL PROCESSES, e.g. CATALYSIS OR COLLOID CHEMISTRY; THEIR RELEVANT APPARATUS
    • B01J19/00—Chemical, physical or physico-chemical processes in general; Their relevant apparatus
    • B01J19/26—Nozzle-type reactors, i.e. the distribution of the initial reactants within the reactor is effected by their introduction or injection through nozzles
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B01—PHYSICAL OR CHEMICAL PROCESSES OR APPARATUS IN GENERAL
    • B01F—MIXING, e.g. DISSOLVING, EMULSIFYING OR DISPERSING
    • B01F25/00—Flow mixers; Mixers for falling materials, e.g. solid particles
    • B01F25/30—Injector mixers
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B01—PHYSICAL OR CHEMICAL PROCESSES OR APPARATUS IN GENERAL
    • B01F—MIXING, e.g. DISSOLVING, EMULSIFYING OR DISPERSING
    • B01F25/00—Flow mixers; Mixers for falling materials, e.g. solid particles
    • B01F25/40—Static mixers
    • B01F25/45—Mixers in which the materials to be mixed are pressed together through orifices or interstitial spaces, e.g. between beads
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B01—PHYSICAL OR CHEMICAL PROCESSES OR APPARATUS IN GENERAL
    • B01J—CHEMICAL OR PHYSICAL PROCESSES, e.g. CATALYSIS OR COLLOID CHEMISTRY; THEIR RELEVANT APPARATUS
    • B01J19/00—Chemical, physical or physico-chemical processes in general; Their relevant apparatus
    • B01J19/02—Apparatus characterised by being constructed of material selected for its chemically-resistant properties
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B01—PHYSICAL OR CHEMICAL PROCESSES OR APPARATUS IN GENERAL
    • B01J—CHEMICAL OR PHYSICAL PROCESSES, e.g. CATALYSIS OR COLLOID CHEMISTRY; THEIR RELEVANT APPARATUS
    • B01J2219/00—Chemical, physical or physico-chemical processes in general; Their relevant apparatus
    • B01J2219/00002—Chemical plants
    • B01J2219/00004—Scale aspects
    • B01J2219/00006—Large-scale industrial plants
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B01—PHYSICAL OR CHEMICAL PROCESSES OR APPARATUS IN GENERAL
    • B01J—CHEMICAL OR PHYSICAL PROCESSES, e.g. CATALYSIS OR COLLOID CHEMISTRY; THEIR RELEVANT APPARATUS
    • B01J2219/00—Chemical, physical or physico-chemical processes in general; Their relevant apparatus
    • B01J2219/00049—Controlling or regulating processes
    • B01J2219/00051—Controlling the temperature
    • B01J2219/00054—Controlling or regulating the heat exchange system
    • B01J2219/00056—Controlling or regulating the heat exchange system involving measured parameters
    • B01J2219/00058—Temperature measurement
    • B01J2219/00063—Temperature measurement of the reactants
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B01—PHYSICAL OR CHEMICAL PROCESSES OR APPARATUS IN GENERAL
    • B01J—CHEMICAL OR PHYSICAL PROCESSES, e.g. CATALYSIS OR COLLOID CHEMISTRY; THEIR RELEVANT APPARATUS
    • B01J2219/00—Chemical, physical or physico-chemical processes in general; Their relevant apparatus
    • B01J2219/00049—Controlling or regulating processes
    • B01J2219/00051—Controlling the temperature
    • B01J2219/00074—Controlling the temperature by indirect heating or cooling employing heat exchange fluids
    • B01J2219/00119—Heat exchange inside a feeding nozzle or nozzle reactor
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B01—PHYSICAL OR CHEMICAL PROCESSES OR APPARATUS IN GENERAL
    • B01J—CHEMICAL OR PHYSICAL PROCESSES, e.g. CATALYSIS OR COLLOID CHEMISTRY; THEIR RELEVANT APPARATUS
    • B01J2219/00—Chemical, physical or physico-chemical processes in general; Their relevant apparatus
    • B01J2219/00049—Controlling or regulating processes
    • B01J2219/00051—Controlling the temperature
    • B01J2219/00121—Controlling the temperature by direct heating or cooling
    • B01J2219/00123—Controlling the temperature by direct heating or cooling adding a temperature modifying medium to the reactants
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B01—PHYSICAL OR CHEMICAL PROCESSES OR APPARATUS IN GENERAL
    • B01J—CHEMICAL OR PHYSICAL PROCESSES, e.g. CATALYSIS OR COLLOID CHEMISTRY; THEIR RELEVANT APPARATUS
    • B01J2219/00—Chemical, physical or physico-chemical processes in general; Their relevant apparatus
    • B01J2219/00049—Controlling or regulating processes
    • B01J2219/00164—Controlling or regulating processes controlling the flow
    • B01J2219/00166—Controlling or regulating processes controlling the flow controlling the residence time inside the reactor vessel
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B01—PHYSICAL OR CHEMICAL PROCESSES OR APPARATUS IN GENERAL
    • B01J—CHEMICAL OR PHYSICAL PROCESSES, e.g. CATALYSIS OR COLLOID CHEMISTRY; THEIR RELEVANT APPARATUS
    • B01J2219/00—Chemical, physical or physico-chemical processes in general; Their relevant apparatus
    • B01J2219/02—Apparatus characterised by their chemically-resistant properties
    • B01J2219/0204—Apparatus characterised by their chemically-resistant properties comprising coatings on the surfaces in direct contact with the reactive components
    • B01J2219/0209—Apparatus characterised by their chemically-resistant properties comprising coatings on the surfaces in direct contact with the reactive components of glass
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B01—PHYSICAL OR CHEMICAL PROCESSES OR APPARATUS IN GENERAL
    • B01J—CHEMICAL OR PHYSICAL PROCESSES, e.g. CATALYSIS OR COLLOID CHEMISTRY; THEIR RELEVANT APPARATUS
    • B01J2219/00—Chemical, physical or physico-chemical processes in general; Their relevant apparatus
    • B01J2219/02—Apparatus characterised by their chemically-resistant properties
    • B01J2219/0204—Apparatus characterised by their chemically-resistant properties comprising coatings on the surfaces in direct contact with the reactive components
    • B01J2219/0245—Apparatus characterised by their chemically-resistant properties comprising coatings on the surfaces in direct contact with the reactive components of synthetic organic material

Definitions

  • the present invention relates to a method of reacting natural gas and oxidant under conditions to optimize the formation of desired alkyl oxygenates (especially, methanol). More specifically, the embodiments are for reacting a Ci - C 4 alkane (methane, ethane, propane, and butane) into an alkyl oxygenate, and, more particularly in a focal application, for direct oxidation (under partial oxidation conditions) conversion of methane into methanol.
  • a Ci - C 4 alkane methane, ethane, propane, and butane
  • the current industrial practice for methanol production is a two-step,
  • 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 economics are unfavorable for all but very large scale methanol plants.
  • Russian Patent No. 2,162,460 includes a source of hydrocarbon- containing gas, a compressor and a heater for compression and heating of the gas, and a source of oxygen-containing gas with a compressor.
  • It further includes successively arranged reactors with alternating mixing and reaction zones and a means to supply the hydrocarbon-containing gas into a first mixing zone of the reactor and the oxygen-containing gas into each mixing zone, a recuperative heat exchanger for cooling of the reaction mixture through a wall by a stream of cold hydrocarbon- containing gas of the heated hydrocarbon-containing gas into a heater, a cooler- condenser, a partial condenser for separation of waste gasses and liquid products with a subsequent separation of methanol, a pipeline for supply of the waste gas into the initial hydrocarbon-containing gas, and a pipeline for supply of waste oxygen-containing products into the first mixing zone of the reactor.
  • the apparatus also requires burning an additional quantity of the initial hydrocarbon-containing gas in order to provide the utility needs of a rectification of liquid products. Since it is necessary to cool the gas-liquid mixture after each reactor for separation of liquid products and subsequent heating before a next reactor, the apparatus is substantially complicated and the number of units is increased.
  • a further method and apparatus for producing methanol is disclosed in the patent document RU 2,200,731 , in which compressed heated hydrocarbon-containing gas and compressed oxygen-containing gas are introduced into mixing zones of successively arranged reactors, and the reaction is performed with a controlled heat pick-up by cooling of the reaction mixture with water condensate so that steam is obtained, and a degree of cooling of the reaction mixture is regulated by parameters of escaping steam, which is used in liquid product rectification stage.
  • 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 disclose further solutions for transformation of hydrocarbons.
  • United States Patent 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.
  • the selectivity for methanol is indicated as resulting from careful premixing of methane and oxygen along with the use of glass-lined reactors to minimize interactions with the processing equipment during the reaction.
  • the need for mixing prior to entering a reactor for reaction initiation is indicated in the following extract:
  • United States Patent 4,618,732 to Gesser also emphasizes the need to keep the reaction from initiation until mixing is completed ( — “mixing oxygen and natural gas prior to their introduction into a reactor”).
  • United States Patent 4,982,023 (“Oxidation of methane to methanol” to Han, et al.) brings forth that a plurality of reactions is occurring in the direct oxygenation of methane to methanol.
  • United States Patent 4,982,023 indicates some consideration of reaction-kinetics issues in the discussion of that patent's subject matter:
  • alkyl oxygenate e.g., without limitation, ethanol, formaldehyde, and/or ethanol
  • alkane e.g., without limitation, methane, ethane, propane, and butane
  • the method comprises providing a reactor system having an injectively-mixed backmixing reaction chamber in fluid communication with a tubular-flow reactor; feeding the alkane- containing feed stream and the oxygen-containing feed stream to the injectively-mixed backmixing reaction chamber; inducing alkyl free radical formation in the injectively- mixed backmixing reaction chamber to yield an injectively-mixed backmixing reaction chamber product stream comprising oxygen, the alkane, and at least a portion of the alkyl free radicals; feeding the injectively-mixed backmixing reaction chamber product stream to a tubular-flow reactor; and reacting the injectively-mixed backmixing reaction chamber product stream into the alkyl oxygenate in the tubular-flow reactor.
  • the feeding of the alkane-containing feed stream and the oxygen-containing feed stream injectively intermixes the alkane-containing feed stream and the oxygen-containing feed stream to thereby turbulently agitate the injectively-mixed backmixing reaction chamber.
  • the feeding of the injectively-mixed backmixing reaction chamber product stream fluidly conveys the backmixing reaction chamber product stream through a flow restriction baffle.
  • the reactor system has a space-time for the inducing and the reacting, respective to a combined feed rate of the alkane-containing feed stream and the oxygen-containing feed stream, of not greater than 40 seconds.
  • the tubular-flow reactor has a tubular-flow reactor input and a tubular-flow reactor output
  • the method further comprises quenchably cooling the tubular-flow reactor with a cooling gas stream received from a cooling gas input disposed at a location between the tubular-flow reactor input and the tubular-flow reactor output.
  • the cooling is achieved by axially adjusting the location of the cooling gas input during operation of the tubular-flow reactor.
  • the tubular-flow reactor discharges a reaction product stream from the tubular-flow reactor output, and the method further comprises scrubbing the reaction product stream with a liquid absorbent to remove methanol from the reaction product stream.
  • the absorbent further absorbs carbon dioxide and/or formaldehyde from the reaction product stream.
  • the method further comprises recycling a recycle stream from the scrubber to the alkane-containing feed stream (preferably to provide a weight percentage proportion of from about 4:5 to about 20:21 of alkane in the alkane-containing feed stream).
  • the injectively-mixed backmixing reaction chamber has a backmixing reaction chamber housing and a bulkhead in slideably- sealed interface to the backmixing reaction chamber housing, the injectively-mixed backmixing reaction chamber has an injectively-mixed backmixing reaction chamber internal volume defined by the backmixing reaction chamber housing and by the bulkhead, and the backmixing reaction chamber housing has a housing portion in opposite disposition to the bulkhead.
  • the inducing further comprises either (a) slideably moving the bulkhead during real-time operation of the reactor system to progress within the injectively-mixed backmixing reaction chamber housing toward the housing portion to commensurately diminish the injectively-mixed backmixing reaction chamber internal volume, or (b) slideably moving the bulkhead during real-time operation of the reactor system within the injectively-mixed backmixing reaction chamber housing to retract away from the housing portion to thereby commensurately expand the injectively-mixed backmixing reaction chamber internal volume.
  • the feeding of the alkane-containing feed stream further comprises pressurizing the alkane-containing gas feed stream with a centrifugal blower prior for input to the injectively-mixed backmixing reaction chamber.
  • Figure 1 schematically shows a system of an apparatus for producing alkyl oxygenate (e.g., without limitation, methanol) in accordance with the present teachings;
  • alkyl oxygenate e.g., without limitation, methanol
  • Figures 2 and 3 are views illustrating concentrations of oxygen, formaldehyde, and methanol during reactions in accordance with the prior art and in accordance with the present invention correspondingly;
  • Figure 4 represents a graph depicting the yield oxygenates of the system as a function of recycle ratio
  • Figure 5 represents an alternate Ci - C 4 alkane to alkyl oxygenate plant according to the teachings of the present invention.
  • Figure 6 represents an optional oxygen producing plant shown in Figure 5;
  • Figure 7 depicts a gas processing portion of the plant shown in Figure
  • Figure 8 represents the liquid processing portion of the plant shown in Figure 5;
  • Figure 9 represents another alternate Ci — C 4 alkane (e.g., without limitation, methane) to alkyl oxygenate (e.g., without limitation, methanol) plant according to the teachings of the present invention;
  • Figure 10 represents yet another alternate Ci - C 4 alkane (e.g., without limitation, methane) to alkyl oxygenate (e.g., without limitation, methanol) plant according to the teachings of the present invention
  • Figure 11 represents yet another alternate C 1 — C 4 alkane (e.g., without limitation, methane) to alkyl oxygenate (e.g., without limitation, methanol) plant according to the teachings of the present invention
  • Figure 12 presents a cross section simplified view of one embodiment of a reactor system having an injectively-mixed backmixing reaction chamber in close coupling to a tubular-flow reactor;
  • Figures 13A and 13B presents cross section simplified views of details in modifying the internal volume of the injectively-mixed backmixing reaction chamber of Figure 12;
  • Figure 14A presents a cross section simplified view of an alternative design for the injectively-mixed backmixing reaction chamber of Figure 12;
  • Figure 14B shows a view of the injectively-mixed backmixing reaction chamber of Figure 12 with a modified internal volume from that shown in Figure 12;
  • Figures 15A and 15B present a cross section simplified view of a
  • Figure 16 presents a cross section simplified view of internal fluid passageways for the conical fluid delivery insert for the injectively-mixed backmixing reaction chamber of the reactor system embodiments of Figures 12 and 20;
  • Figures 17A and 17B presents a cross section simplified view of baffle details and positioning at the interface between the injectively-mixed backmixing reaction chamber and the tubular-flow reactor of the reactor system embodiments of Figures 12 and 20;
  • Figures 18A and 18B presents a cross section simplified view of details and positioning for one variable position quenching inlet of the reactor system embodiments of Figures 12 and 20;
  • Figures 19A - 19C present a series of temperature profiles for the tubular-flow reactor of the reactor system embodiments of Figures 12 and 20;
  • Figure 20 presents a cross section simplified view of an alternative embodiment of a reactor system having an injectively-mixed backmixing reaction chamber in close coupling to a tubular-fl ⁇ w reactor;
  • Figure 21 presents bulkhead/baffle details for an embodiment of the interface between the injectively-mixed backmixing reaction chamber and the tubular- flow reactor of the reactor system embodiments of Figures 12 and 20;
  • Figures 22A - 22C shows axial positioning detail for the interface between the injectively-mixed backmixing reaction chamber and the tubular-flow reactor of the Figure 20 reactor system embodiment;
  • Figure 23 shows further detail in the quenching inlet for the Figure 20 reactor system embodiment;
  • Figures 24A and 24B show axial view detail for the Figure 20 reactor system embodiment.
  • Figures 25A and 25B show views of tubular-flow reactor systems having injectively-mixed entry zones, multi-position quenching, and multi-position temperature sensing.
  • the words "preferred” and “preferably” refer to embodiments of the invention that afford certain benefits, under certain circumstances. However, other embodiments may also be preferred, under the same or other circumstances. Furthermore, the recitation 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.
  • the embodiments relate to direct oxygenation conversion of at least one Ci - C 4 alkane into as least one alkyl oxygenate.
  • the direct oxygenation conversion of methane into methanol is a focal conversion goal of the technology.
  • One apparatus for producing methanol in accordance with the present invention has a reactor 100 facilitating a gas phase oxidation of a hydrocarbon- containing gas as shown in Figure 1.
  • a heated hydrocarbon- containing gas stream from valve 120 and heater 136) and an oxygen-containing gas from line 29 are introduced into reactor 100.
  • the oxygen- containing gas preferably has greater than 80% oxygen content to reduce the accumulation of inert gases by the recycling process.
  • the reactor 100 further optionally receives a quenching cold hydrocarbon-containing gas stream from valve 120 and heat exchanger 121 for reducing the temperature of reaction during operation of the apparatus.
  • the apparatus has a device 114 for cooling the reaction product stream mixture before separation. Additionally, partial condenser 122 incorporates a gas-liquid heat exchanger to further reduce the temperature of the products.
  • the condenser 122 separates H 2 O and alcohols from a hydrocarbon-CO 2 mixture.
  • the partial condenser 122 is preferably isobaric, as opposed to isothermal, to avoid pressure losses.
  • the reaction product stream enters, and a liquid stream and gaseous stream exit condenser 122.
  • Block 139 represents equipment that is configured to separate contaminants and products from a hydrocarbon-containing recycle gas component.
  • the equipment 139 is configured to remove COg from the reduced product stream.
  • the equipment 139 can take the form of a purge valve, absorber, membrane separator, or an adsorber. It is envisioned the equipment 139 can be used to regulate the percentage of other non-reactive components such as N 2 with, for example, a purge valve.
  • the gaseous reduced product stream leaves the isobaric condenser 122 and is passed to the scrubber 134.
  • Other potential methods that can be utilized use materials such as various amines known to remove COaand formaldehyde.
  • modification of the flow rate of methanol or operating temperature of the scrubber column can be used. If it is desirable to operate at extremely low absorbent flow rates, then a lower temperature can be utilized, for example 0 0 C. If it is desirable to operate at ambient temperatures or temperatures achievable via cooling water, then a high flow rate can be utilized, for example, ten times that of the flow rate for 0 0 C. In either scenario, the pregnant methanol absorbent stream 14 is completely regenerated by the formaldehyde distillation column 138.
  • the stream 14 from the scrubber 134 can be passed through the condenser 122 to provide cooling of the product stream and preheating of the methanol recycle to improve the energy efficiency of the formaldehyde distillation column 138.
  • the reactor 100 is connected with a compressor 124 and heater 126 for supply of compressed and heated oxygen-containing gas.
  • the raw hydrocarbon- containing gas is mixed with cleaned hydrocarbon gas from the scrubber 134 and is heated using a heater 136.
  • the raw hydrocarbons can be mixed with the reduced product hydrocarbon stream from the condenser 122 prior to the entry of the scrubber 134 for removal of contaminant gases prior to entering the reactor.
  • the apparatus further has a unit for rectification of methanol that includes a flash drum 132, rectification column 128, and a vessel 130 from which methanol is supplied to storage or further processing.
  • This rectification column 128 is used to separate methanol (light-key component) from ethanol (heavy-key component) and water (non-key component).
  • methanol light-key component
  • ethanol heavy-key component
  • water non-key component
  • Stream 8 has some amount of ethanol (and perhaps methanol, if ultra pure methanol was produced) and will be used as the basis of the aqueous makeup of the commercial formalin stream (stream 11 and formalin storage 191 ). In this manner, some of the ethanol is recovered before the remainder is discarded in the liquid waste stream.
  • a flash drum 132 Disposed between the column 128 and the condenser 122 is a flash drum 132 for removal of CO 2 and formaldehyde from the liquid product stream.
  • the purpose of the flash drum 132 is to drop the pressure to an appropriate level before entry into the methanol rectification column 128 and to substantially remove any dissolved gases, typically CO 2 and formaldehyde, from the liquid product stream.
  • the raw hydrocarbon-containing gas stream with a methane content for example up to 98% and the reduced hydrocarbon product stream are supplied from an installation for preparation of gas or any other source to the heater 136, in which it is heated to temperature 430-470°C.
  • the heated hydrocarbon-containing gas is then supplied into reactor 100.
  • Compressed air with pressure, for example, of 7-8 MPa and with a ratio 80% to 100% and, preferably, 90% to 95% oxygen is supplied by the compressor 124 also into reactor 100.
  • Oxidation reaction of methane to methanol and/or formaldehyde takes place in reactor 100.
  • the O 2 stream is preferably substantially pure, thus limiting the amount of N 2 entering the system.
  • An optional second stream of cold (or, in other words, a lower temperature coolant than the gases) coolant in the reactor is supplied into reactor 100 as previously outlined.
  • This stream is regulated by the regulating device (valve) 120, that can be formed as a known gas supply regulating device, regulating valve, or the like.
  • This cold stream can be, for example, composed of a raw hydrocarbon stream, a recycled stream, or a portion or combination of the two.
  • the regulator is configured to adjust the volume or pressure of cold hydrocarbon-containing gas based on system parameters such as, but not limited to, pressure, temperature, or reaction product percentages at a location further down-stream in the system.
  • the coolant which is supplied from a coolant source, functions to reduce the temperature of the partially oxidized methane to reduce the continued oxidation or decomposition of formaldehyde.
  • This coolant can be any material that can easily be separated from the reaction product stream.
  • the coolant can be an unheated hydrocarbon or methane containing gas stream.
  • the coolant can be any non-oxidizing material easily separated from the reaction products.
  • the coolant can be gaseous, an aerosol, or misted liquid of, for example, CO 2 , formaldehyde, methanol, water, and/or steam. It is additionally envisioned that the coolant can further be a mixture of recycied reaction products, water, steam, and/or raw hydrocarbon gases.
  • the reaction mixture is subjected to the reaction in the reactor without the introduction of the cold hydrocarbon-containing gas if it is desired to essentially/exclusively produce methanol.
  • the introduction of the cold hydrocarbon-containing gas is used when methanol and formaldehyde are both desired as products.
  • the temperature of the reaction is reduced, for example by 30-90°Celsius, so as to preserve the content of formaldehyde in the separated mixture by reducing the decomposition of the formaldehyde into CO 2 .
  • the reaction mixture is supplied into the heat exchanger 114 for transfer of heat to the reactor input stream from the reaction mixture exiting the reactor, and, after further cooling, is supplied to partial condenser 122. Separation of the mixture into high and low volatility components (dry gas and raw liquid, respectively) is performed in the partial condenser 122 that may absorb at least some of the formaldehyde into the raw liquid stream as desired.
  • the dry gas is forwarded to a scrubber 134, while the raw liquids from the condenser 122 are supplied to the flash drum 132.
  • Scrubber 134 functions to remove the CO 2 and formaldehyde from the dry gas stream.
  • the scrubber 134 uses both H 2 O and methanol at between 7-8 MPa pressure and between about 0 0 C and about 50 0 C to absorb CO 2 and formaldehyde.
  • the reduced stream of hydrocarbon gas is recycled by mixing the reduced stream with the raw hydrocarbon- containing gas stream either before or within the reactor, as desired.
  • the raw hydrocarbon and reduced streams, individually or in combination, are then inputted into reaction chamber 100 at after being heated by heat exchanger 116 and heater 136 as previously described.
  • Rectification column 138 is used to separate carbon dioxide (non-key component) and formaldehyde (light-key component) from methanol (heavy-key component) and water (non-key component).
  • the pregnant methanol steam, stream 14 enters rectification column 138 and is separated into formaldehyde distillate stream 16 and bottoms stream 15.
  • Some amount of methanol in the distillate stream is desirable since methanol is used as a stabilizer for the production of commercial grade formalin (6-15% alcohol stabilizer, 37% formaldehyde, and the balance being water).
  • stream 15 is supplemented by stream 31 so as to replace any methanol that was transferred to the distillate stream, stream 16. Combining stream 31 and stream 15 results in stream 17, which then returns to the scrubber 134 as regenerated methanol absorbent. Meanwhile, the formaldehyde distillate, stream 16, combines with the vapors from flash drum 132, stream 7, to form a mixture of formaldehyde, methanol, and carbon dioxide.
  • Free or non-aqueous formaldehyde is allowed to remain in the gas phase by operation of the isobaric condenser 122.
  • the liquid methanol product stream, or raw liquids therefore comprise methanol, ethanol, and water insofar as formaldehyde remains in the gaseous stream.
  • the liquid stream exiting the isobaric condenser 122 can bypass the formaldehyde rectification portion of the process and enter the methanol rectification column after having optionally passed through the flash drum 132.
  • Figures 2 and 3 show diagrams of the concentration of oxygen, formaldehyde and methanol in reactions without cooling and with cooling, respectively.
  • Figure 4 represents a graph depicting the yield of oxygenates for the system as a function of the recycle ratio of the recycling hydrocarbon gasses. Shown is a graph depicting the use of Michigan Antrim gas having 97% CH 4 and 1% N 2 . In this regard, the graph shows a significant increase in product yield using the same input stream and with little increase in capital costs. As the system efficiently manages pressure and integrates process energy usage, energy requirements are minimized, thus increasing the overall system economics.
  • Figure 5 represents an alternate methane to methanol plant 150.
  • the plant 150 is positioned to process methane from gas being discharged from either a combined oil and gas field 152 or the gas field 154.
  • the plant 150 which is preferably located in close proximity to the well bore, is generally formed of a gas processing plant 156, a liquid processing plant 158, and an oxygen producing plant 160. Additionally associated with the plant 150 are waste water treatment and utility plants 162 and 164.
  • an optional oxygen producing plant 160 can be used to assist in the regulation of the partial oxidation of the hydrocarbon stream in the reactor 100.
  • the oxygen producing plant 160 has a compressor 161 coupled to a heat exchanger 163 which functions to prepare the compressed oxygen for injection into a plurality of absorbers 165. After passing through the absorbers, the produced oxygen stream is compressed and forwarded directly to the reactor 100.
  • the gas processing portion of the plant 156 generally functions as described above (see Figure 1). In this regard, the gas processing plant 156 has compressors 170 and 172 for raising the pressure of a cleaned incoming hydrocarbon stream 174.
  • This stream 174 is then divided and reacted with oxygen in the reactor 100 to partially oxidize methane as described above. It is envisioned that the parameters such as time of reaction and temperature and pressure within the reactor can be adjusted to selectively control the amount of CO 2 , H 2 O, formaldehyde and methanol that are produced in the reactor 100.
  • the reaction products 176 from the reactor are then transferred to the liquid processing plant 158.
  • the liquid processing plant 158 generally functions as described above to separate the methanol and formaldehyde from the reaction product stream 176. Shown are associated distillers, blenders and flash drums that are used to separate the constituent materials of the reaction product stream as described in detail above. Specifically, CO 2 is removed from the reaction product stream as are methanol and, if desired, formaldehyde.
  • the scrubber 134 (see Figure 5) prevents the accumulation of CO 2 and allows the physical capture of formaldehyde.
  • the scrubber 134 can utilize a mixture of methanol and water to physically absorb formaldehyde and CO 2 from the hydrocarbon gas recycle loop 135.
  • the efficiency of the scrubber 134 which can operate adequately without refrigeration, is made possible due to the high operating pressure of the recycle loop 135. This is opposed to cryogenically low temperatures utilized by traditional absorption processes.
  • the gases enter the scrubber 134 as a "dirty" gas with some amount of formaldehyde and CO 2 present. These components will only be present in relatively dilute amounts, so the duty of the methanol absorbent is also relatively small.
  • the output of the reactor can be selectively adjusted so as to minimize the amount of formaldehyde being produced by the gas process portion of the plant 156.
  • the CO 2 can be vented, it is specifically envisioned that the CO 2 from the reaction products can be injected, at a predetermined distance from the well, into the ground to increase the output of the well.
  • the CO 2 can be injected at any appropriate distance from the well so as to allow for the increase of subterranean pressures to increase the gas or oil output of the well.
  • the CO 2 can be injected into the casement of the wellbore or in the near-wellbore zone, to increase the output of the gas or oil and gas producing well.
  • the plant 150 can be associated with an off-shore oil rig.
  • the plant 150 would either be on the off-shore rig or would be a predetermined short distance from the rig, such as immediately adjacent to the off-shore rig on a floatable platform.
  • the methanol converted from the methane containing hydrocarbon stream would be injected into a second portion of the methane containing hydrocarbon stream to improve the flow of the hydrocarbon stream from the off-shore oil well to land. This methanol is injected to reduce the formation of hydrates within the piping.
  • any of the other reaction products namely, CO 2 , water or methanol can be injected directly into the hydrocarbon containing subterranean formations surrounding the platform or a land-based well.
  • methanol can be injected into hydrate structures surrounding the well so as to increase the output of natural gas from a natural gas producing well.
  • the CO 2 can be injected into one portion of the well while methanol or other reaction products can be injected into other portions of the welt.
  • facilities may be provided to manage nitrogen build-up in the recycle loop.
  • a single plant 100 having a truncated process can be used. In these situations, only portions of the facility related to the partial oxidation of the hydrocarbon stream and associated facilities to remove CO 2 will be used near the well.
  • Removed CO 2 can be collected, vented or reinjected into the ground.
  • the remaining liquid products can be transported in liquid form from the well site to another location for separation of formaldehyde, methanol and water from the waste stream.
  • a centralized liquid processing plant to finalize the processing of the liquid processes can be located at a significant distance from the stranded natural gas locations. This allows for the use of a centralized liquid process facility 158. It is also envisioned that the conditions of the reactor can be adjusted to produce a liquid phase that contains a commercial grade of formalin.
  • Air 902 is input to compressor 934 and then cooled in heat exchanger 904 for delivery to one of nitrogen separator 906 or nitrogen separator 908.
  • Oxygen feed is stored in tank 962 and compressed with compressor 910 for introduction as an oxygen-containing feed stream into reactor system 914 after heating in heater 912.
  • Alkane-containing raw feed 926 (at least one C 1 - C 4 alkane, primarily methane or natural gas) is compressed in compressor 928 and blended with scrubber 920 alkane recycle for further pressurization in compressor 922 and thermal cross exchange with reactor product stream reactor 936 in heat exchanger 930.
  • the recycle stream preferably provides a weight percentage proportion of from about 4:5 to about 20:21 of alkane in the alkane- containing feed stream to reactor 914.
  • compressor 922 can be a centrifugal blower (non-positive displacement compressor). After thermal cross exchange with reactor product stream reactor 936 in heat exchanger 930, the combined raw alkane and recycle stream is heated in heat exchanger 932 to provide an alkane-containing feed stream to reactor system 914.
  • Embodiments of reactor system 914 are further described in Figures 12 - 24B.
  • Scrubber 920 operates to absorb carbon dioxide and alkyl oxygenates (for example, without limitation, methanol, ethanol, and formaldehyde) while providing a recycle stream for combination with fresh alkane to provide a feed stream to compressor 922.
  • a purge at valve 924 removes non-reactive inerts (e.g., without limitation, nitrogen) from the reactor-scrubber process loop to augment efficient use of reactor system 914.
  • a cooling quench to reactor system 914 is also optionally enabled from valve 938.
  • Liquid bottoms from scrubber 920 are forwarded to flash drum 918 where overhead steam 942 separates from product stream 940 (comprising for example and without limitation, methanol, ethanol, and formaldehyde).
  • Furnace or thermal oxidizer 916 oxidizes waste gases for discharge to the atmosphere.
  • Process 900 is useful for providing a liquid material for further processing at another location into purified alkane oxygenates or for providing an alkane oxygenate blend useful for a fuel or other similar use where exact purity is not critical.
  • Figure 10 shows another process embodiment 1000 with a front end process loop essentially similar to process 900 presented in Figure 9, but incorporating an in-situ distillation system 1002 for separating methanol in steam 1004 (for absorbent in the scrubber), purified water in stream 1006 for use in knockdown drum 1012, and generation of purified methanol 1008 and waste stream 1010.
  • Knockdown drum 1012 provides initial separation of liquid from the reactor product stream prior to the introduction of the remainder of the reactor product stream into the scrubber.
  • Figure 11 presents process embodiment 1100 for generating a methanol product stream and formaldehyde with a front end process loop essentially similar to process 900 presented in Figure 9, but incorporating an in-s/tu formaldehyde distillation system 1110 and methanol distillation system 1108 to generate methanol product stream 1102.
  • the stream from methanol distillation system 1108 cools formaldehyde distillation system 1110 overheads to separate carbon dioxide (product stream 1106) and formaldehyde (product stream 1104) in absorber-blender 1116.
  • a recycle stream of methanol to the scrubber is drawn from methanol distillation system 1108 and chilled in chiller 1112 to provide a high-efficiency scrubber for condensing the reactor product stream.
  • Furnace or thermal oxidizer 1114 oxidizes a purge to remove non-reactive inerts (e.g., without limitation, nitrogen) with some alkane (methane) from the reactor-scrubber process loop and thereby augment efficient use of the reactor.
  • non-reactive inerts e.g., without limitation, nitrogen
  • alkane methane
  • the method for reaction comprises passing a mixture of natural gas and oxidant through a heated, continuous flow reactor system under conditions to optimize the formation of methanol, and to manipulate the reactor temperature, total pressure, and fuel (e.g., without limitation, natural gas) to oxidant ratio to control the relative amounts of reaction products.
  • the reaction is a partial oxidation of a C 1 - C 4 fuel, such as natural gas, by an oxidant, oxygen, air, or other suitable oxygen- containing compound (preferably oxygen in air or, most preferably, oxygen).
  • the mixture contains a substantial excess of fuel (e.g., without limitation, natural gas) to prevent complete combustion to undesired products such as carbon dioxide and water.
  • the reaction is an exothermic, branched chain reaction.
  • Chain branching causes an acceleration of the reaction rate via quadratic growth of chain carriers.
  • Reactions of this type are characterized by an induction period during which chain carrier concentrations build up to the point where a very rapid rise in reaction rate and temperature occurs.
  • the very rapid rise in reaction rate is because of the quadratic growth rate of chain carriers, and the very rapid rise in temperature is because of the increase of the rate of heat generation that accompanies the reaction rate.
  • Complete consumption of oxidant, the limiting reagent occurs before the fuel (e.g., without limitation, natural gas) is entirely consumed, which limits the temperature rise.
  • the ratio of oxidant to fuel e.g., without limitation, natural gas
  • the ratio of oxidant to fuel is arranged so that the selectivity fir formation of methanol is optimized.
  • Reaction conditions favoring the best selectivity for methanol and other oxygenates are as follows.
  • the composition of the reaction mixture, after combining the alkane-containing fed stream and the oxygen-containing feed stream, should be from about 1 mol% to about 10 mol% oxidant, preferably from about 2 mol% to about 5 mol% oxidant, and most preferably at about 2.5 mol% oxidant.
  • the total pressure of the gases in the reactor system should be in the range of from about 6 MPa to about 10 MPa, preferably from about 7.5 MPa to about 9 MPa, and most preferably at about 8 Mpa.
  • the reactor system wall temperature should be in the range of from about 600 K to about 900 K 1 and more preferably from about 723 K to about 823 K.
  • the overall reactor residence lime should be in the range of from about 1 second to 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.
  • methanol selectivity is in the range of from about 0.35 to at least 0.60 with lower selectivity's for the other oxygenates of the alkane- containing feed stream.
  • the conversion of methane is approximately 10%, and conversion of the other hydrocarbon components of the natural gas is comparable.
  • the fuel e.g., a Ci — C 4 alkane or Ci - C4 alkanes such as provided in natural gas
  • oxidant e.g., a Ci — C 4 alkane or Ci - C4 alkanes such as provided in natural gas
  • a mixing chamber/reactor is supplied for both thoroughly mixing the reaction components and for also inducing the generation of alkyl (e.g., without limitation, methyl) free radicals that are then contained in the output stream from the mixing chamber.
  • alkyl e.g., without limitation, methyl
  • the mixing chamber therefore effectively provides an injectively-mixed backmixing reaction chamber ("backmix reaction chamber") in a reactor system having an injectively-mixed backmixing reaction chamber in fluid communication with a tubular- flow reactor for carrying out the overall reaction.
  • backmix reaction chamber an injectively-mixed backmixing reaction chamber
  • the injectively-mixed backmixing reaction chamber of the embodiments has a number of aspects that indicate an operational character having more of a continuously stirred tank reactor or CSTR model affinity (further denoted as a continuous feed stirred tank reactor or CFSTR; and yet further denoted as a steady-state backmix flow reactor) than of a tubular or plug-flow reactor model affinity.
  • the injectively-mixed backmixing reaction chamber has a space-time, respective to a combined feed rate of the alkane- containing feed stream and the oxygen-containing feed stream, of from about 0.05 seconds to about 1.5 seconds (a preferably contemplated space-time is about 0.1 seconds) so that the feeds can be effectively mixed and so that an initial induction period for generating alkyl free radicals (e.g., without limitation, methyl free radicals) can be accommodated before the injectively-mixed backmixing reaction chamber product stream (methane, oxygen, and methyl free radicals) is fed to the tubular-flow reactor for further reaction into methanol.
  • alkyl free radicals e.g., without limitation, methyl free radicals
  • the design of the injectively- mixed backmixing reaction chamber enables injective intermixing of the Ci - C 4 alkane and oxygen-containing feed streams to turbulently agitate streams together and to effectively turbulently agitate the injectively-mixed backmixing reaction chamber.
  • the generating of methyl free radicals is perceived to be the first kinetic step reaction in the set of kinetic step reactions that achieve direct oxygenation of methane to methanol (one respective alkyl oxygenate), and the use of an injectively-mixed backmixing reaction chamber prior to the tubular-flow reactor enables a degree of freedom for independent optimization of this methyl free radical induction step.
  • the reactor system accordingly provides several degrees of freedom (e.g., without limitation, reactor space-time, temperature, and injective mixing as further subsequently discussed herein) for augmenting the initial, kinetic series sub-reaction(s) and also for augmenting, with some independency from conditions augmenting the initial kinetic series sub-reaction (s), the subsequent kinetic series sub-reactions in the overall set of sub-reactions that combine to achieve the overall direct oxidation reaction of at least one C 1 - C 4 alkane into at least one respective alkyl oxygenate.
  • degrees of freedom e.g., without limitation, reactor space-time, temperature, and injective mixing as further subsequently discussed herein
  • the reactants are fed to the mixing chamber/reactor (the injectively- mixed backmixing reaction chamber) in separate streams. Upon emergence from the injectively-mixed backmixing reaction chamber, the reactants are then fed to the tubular- flow reactor.
  • the mixing must be done thoroughly, with the goal of attaining a uniform or essentially uniform distribution of reactant concentration in the injectively-mixed backmixing reaction chamber product stream. This is necessary to avoid oxidation of the desired products - methanol and other oxygenates. Such oxidation otherwise occurs in incompletely mixed regions where relatively high oxidant concentrations exist, with commensurate reduction of product yield.
  • the mixing time in the injectively-mixed backmixing reaction chamber must be relatively brief compared to the residence time in the tubular-flow reactor.
  • the residence time in the injectively-mixed backmixing reaction chamber must be at least 0.1 second.
  • actual turbulent intermixing of gases can be achieved in as little as 1 ms. While there are several embodiments for achieving satisfactory mixing, as will be hereinafter described, a preferred embodiment for use with the shortest residence times uses essentially opposed turbulent jets with a diverter diffuser cone having its apex-tending side (apexial end) closest to the tubular-flow reactor.
  • the purpose of the cone is to minimize long residence times for sub-portions of the contents of the injectively-mixed backmixing reaction chamber in view of the high reactivity of the alkyl (e.g., methyl) free radicals.
  • the reactor walls must be inert in the chemical environment of the reaction.
  • the reactor construction material must be steel, preferably stainless steel, to contain the necessary total pressure. Insofar as a steel surface diminishes methanol selectivity, the steel is preferably coated with an inert coating, such as TeflonTM, or an organic wax. Insertion of a PyrexTM or quartz sleeve into the reactor also provides a relatively inert surface.
  • a flow restriction baffle is positioned in the injectively-mixed backmixing reaction chamber output to augment pressure drop between the injectively- mixed backmixing reaction chamber and the tubular-flow reactor and thereby achieve a desired residence time fine turning feature (degree of freedom of control) in the injectively-mixed backmixing reaction chamber.
  • the flow restriction baffle (bulkhead with apertures for enabling a fluid passageway) is conveniently axially movable so that alternative baffle positions can be deployed in custom-configuring the effective space-time in the injectively-mixed backrnixing reaction chamber prior to a process run instance or during a process run.
  • the flow restriction baffle is further in close proximity to a blocking component that is conveniently axially movable so that variable baffle (bulkhead) passageways can be defined by partially blocking the apertures in the baffle (bulkhead) in custom-configuring the effective space-time in the injectively-mixed backmixing reaction chamber prior to a process run instance or during a process run; this feature provides another degree of freedom for operational control.
  • the tubular-flow reactor is therefore preferably equipped in one embodiment with a thermocouple that can be translated axially (along the axis of general flow in the reactor) via a sliding seal.
  • a plurality of thermocouples disposed to measure the tubular-flow reactor temperature profile along the axis of flow enable temperature monitoring. The thermocouple set monitors the axial gas phase temperature distribution in the reactor, and the thermocouple measurements are also used for control of the reactor.
  • methanol, formaldehyde and other oxygenates can undergo thermal decomposition in the high temperatures of the tubular-flow reactor, resulting in product loss. Such decomposition is minimized by cooling of the reactor contents at a location immediately downstream from the "hot spot".
  • a preferred embodiment employs injection of a cold gas by means of a tube whose axial position can also be changed by means of a sliding seal.
  • the cold gas is preferably natural gas, but carbon dioxide, nitrogen, or another inert substance may also be used.
  • Figure 12 presents a cross section simplified view 1200 of a reactor system having an injectively-mixed backmixing reaction chamber 1202 in close coupling to a tubular-flow reactor 1204 so that a reactor system having an injectively-mixed backmixing reaction chamber in fluid communication with a tubular-flow reactor is provided for one of the processes described in conjunction with Figures 1 - 11.
  • the main chamber and reactor sections of the reactor system are aligned along axis 1220 with the injectively-mixed backmixing reaction chamber having housing 1206 (defining internal volume 1234 with a cylindrical surface in co-operation with bulkhead 1232).
  • Tubular-flow reactor 1204 has housing 1210 defining internal volume 1248 in co- operation with slideable tubular-flow reactor 1204 section having housing 1208 and with bulkhead 1232.
  • An alkane-containing gas feed stream (a first fluid stream) enters through alkane gas input 1222 and similar alkane gas inputs as depicted.
  • An oxygen- containing gas feed stream (a second fluid stream) enters through oxygen gas input 1224 and conical diverter/distributor 1226.
  • Conical diverter/distributor 1226 has a conical base (base 1614 of Figure 16) connected to a portion of housing 1206 in opposite disposition to bulkhead 1232.
  • a backmixing reaction chamber output is established by bulkhead (baffle) 1232 and passageway 1270 (with its associated fluid passageways shown in more detail in Figures 17A and 17B) and optional blocking component 1230.
  • Bulkhead (baffle) 1232 and optional (for variable passageway definition in real-time operation of the reactor system) blocking component 1230 provide passageways such as passageway 1270 for feeding the injectively-mixed backmixing reaction chamber 1202 product stream to tubular-flow reactor 1204.
  • Tubular-flow reactor 1204 therefore has a tubular-flow reactor input in fluid communication through passageway 1270 with the backmixing reaction chamber 1202 output at bulkhead (baffle) 1232 and blocking component 1230.
  • Alkane gas input 1222 (along with similar alkane gas inputs as depicted) and oxygen gas input 1224 with conical diverter/distributor 1226 and oxygen input aperture 1228 (along with similar alkane gas inputs as depicted) are configured (positioned and sized with respect to the flows of the alkane-containing and the oxygen-containing feed streams) to turbulently agitate reaction components within internal volume 1234 of injectively-mixed backmixing reaction chamber 1202 by injective intermixing of the alkane-containing gas feed stream and the oxygen-containing gas feed stream.
  • Tubular-flow reactor 1204 has a tubular-flow reactor output 1260, and tubular-flow reactor 1204 has cooling gas input 1274 disposed between the tubular-flow reactor input from passageways (passageway 1270) at bulkhead 1232 and tubular-flow reactor output 1260 for receiving a cooling gas stream (that enters at cooling input port 1236 and then into cooling gas internal input port 1250 before proceeding to cooling gas input 1274) and thereby quenchably cooling tubular-flow reactor 1204.
  • cooling gas input 1274 in one embodiment is in an elongated tube (tube 1262) with at least one aperture 1274 (see Figures 18A and 18B for cross-sectional detail respective to axis 1220) for conveying the cooling quench flow into reactor space 1248.
  • Tube 1262 co-operates with guide tube 1264.
  • tube 1262 rotates within guide tube 1264 to regulate the amount of quench delivered to a location.
  • tube 1262 is axially siideable (with reference to axis 1220) to position within tubular-flow reactor 1204 and provide local quenching.
  • tube 1262 rotates within guide tube 1264 to regulate the amount of quench delivered to a location and also is axially siideable (with reference to axis 1220) to position within tubular-flow reactor 1204 and provide local quenching.
  • the quenching components (including drawing references 1262, 1250, 1236, 1264, and 1274) therefore provide a degree of freedom for managing the temperature profile along axis 1220 within tubular-flow reactor 1204.
  • Thermocouples such as thermocouple 1216 and similar thermocouples as depicted provide 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 measurements for the temperature profile in another embodiment.
  • Figure 12 shows an embodiment having stationary thermocouples such as thermocouple 1216 was well as a sliding thermocouple 1214 (with thermocouple head 1272).
  • Tubular-flow reactor 1204 has housing 1210 defining internal volume 1248 in co-operation with the siideable tubular-flow reactor 1204 section having housing 1208 and also having bulkhead 1232 (with optional blocking component 1230 for providing passageway 1270 as a cross-sectionally-variable passageway).
  • Bulkhead 1232 and blocking component 1230 are in slideably-sealed interface to backmixing reaction chamber housing 1206 and are therefore both effectively attached to the siideable tubular-flow reactor 1204 section having housing 1208.
  • Housing section 1208 is therefore in slideably-sealed interface to housing 1210 and also to housing 1206 with seals 1244, 1246, and 1238 providing isolation from the external environment.
  • Injectively-mixed backmixing reaction chamber 1202 has an injectively-mixed backmixing reaction chamber internal volume 1234 defined by backmixing reaction chamber housing 1206 and by bulkhead 1232 (with optional blocking component 1230).
  • Bulkhead 1232 (and blocking component 1230) is therefore slideably movable during real-time operation of the reactor system of view 1200 to progress within backmixing reaction chamber housing 1206 toward input 1224 to thereby commensurately diminish internal volume 1234, and bulkhead 1232 (and blocking component 1230) is alternatively slideably movable during real-time operation to retract away from input 1224 to thereby commensurately expand internal volume 1234.
  • tubular-flow reactor 1204 has a tubular-flow reactor internal volume 1248 defined by tubular-flow reactor housings 1208 and 1210 and by bulkhead 1232 (with blocking component 1230).
  • Bulkhead 1232 (and blocking component 1230) is therefore slideably movable during real-time operation of the reactor system of view 1200 to thereby commensurately diminish internal volume 1248 when moving away from toward input 1224, and bulkhead 1232 (with optional blocking component 1230) is alternatively slideably movable during real-time operation to move toward input 1224 to thereby commensurately expand internal volume 1248.
  • This moveable interface enables a degree of freedom for managing relative space-time (essentially equivalent, for gaseous flow, to internal reaction volume divided by volumetric flow rate moving through that internal reaction volume) within the reactor system of view 1200 between both tubular- flow reactor 1204 and injectively-mixed backmixing reaction chamber 1202.
  • the functionality enabled by the features of bulkhead 1232 (and blocking component 1230) is for a backmixing reaction chamber where the internal volume (defined by an internal surface of a housing and also by the surface of any component in moveably sealed interface to that internal surface) can be readily modified so that the space-time, provided by the backmixing reaction chamber to chemically reacting compositional components in gaseous fluids flowing within the internal volume, can be modified without necessarily modifying flow rate(s), turbulency, and/or pressure drop of those fluids.
  • any approach for modifying the internal volume from a first internal volume to a second internal volume is potentially useful.
  • conical diverter/distributor 1226 has a base wide enough to slideably seal against backmixing reaction chamber housing 1206, conical diverter/distributor 1226 has a slideable tube (not shown) interconnecting to input 1224, and conical diverter/distributor 1226 thereby commensurately diminishes internal volume 1234 when moving away from input 1224 and commensurately expandes internal volume 1234 when moving toward input 1224.
  • housing 1206 has a movable portion that invades into the chamber to diminish internal volume 1234 and alternatively withdraws from the chamber to increase internal volume 1234.
  • an internal diaphramed component modifies its characteristics to commensurately modify internal volume 1234.
  • Seal 1246, seal 1212, seal 1244, seal 1238, seal 1242, and seal 1240 all enable slideable movement of the movable components of the reactor system of view 1200.
  • Rotation component 1218 enables rotation of blocking component 1230 during operation.
  • movement of components is preferably achieved with assistance from variable speed motors, levers, levers with associated gearing, and/or step-motors and with associated gearing (not shown but that should be apparent to those of skill).
  • an alkane-containing feed stream and an oxygen- containing feed stream are input to injectively-mixed backmixing reaction chamber 1202 through input ports such as input 1222 (alkane-containing feed stream) and input 1224 (oxygen-containing feed stream).
  • injectively-mixed backmixing reaction chamber 1202 internal conditions are managed to induce alkyl free radical formation in injectively- mixed backmixing reaction chamber 1202 to yield an injectively-mixed backmixing reaction chamber product stream for output and fluid communication into tubular-flow reactor 1204 through passageways such as passageway 1270 in bulkhead 1232 and blocking component 1230.
  • the components are sized and arranged to provide significant molecular momentum in the entering fluids so that injective mixing and a turbulent reaction fluid in injectively-mixed backmixing reaction chamber 1202 are established.
  • the injectively-mixed backmixing reaction chamber product stream feed to tubular-flow reactor 1204 via passageway 1270 therefore comprises oxygen, unreacted alkane, and at least a portion of the alkyl free radicals that were induced in injectively- mixed backmixing reaction chamber 1202.
  • the "reaction" of alkane to alkyl oxygenate involves a large plurality of short-term reactions (termed herein also as kinetic series sub-reactions or kinetic sub- reactions); indeed, there may be at least 60 kinetic series sub-reactions in the overall "reaction" of methane to methanol and other alkyl oxygenates occurring in the system.
  • the initial kinetic series sub-reaction occurs to induce an alkyl radical from an alkane when an alkane molecule is exposed to molecular oxygen.
  • This inducing of an alkyl radical appears to require a period of time many orders of magnitude in excess of the time needed to turbulently mix the two fluid feed streams, and also appears to be a time- consuming kinetic series sub-reaction respective to the kinetic series sub-reactions that occur once the alkyl free radical is available.
  • the injectively-mixed backmixing reaction chamber provides the reaction components with an essentially universal compositional and physical (temperature, pressure, and molecular momentum) operational state within its space-time compared to a tubular-flow system; this enables management of the critical alkyl radical induction step independently from the tubular-flow reactor where, along the axis of the tubular- flow reactor, the reaction components have an axially (and probably radially) differentiated composition and physical state.
  • the overall reactor system space-time is not greater than 40 seconds, and is preferably not greater than 2.5 seconds.
  • Reaction space-time for the injectively-mixed backmixing reaction chamber is managed to be not greater than 1.5 seconds.
  • Figures 13A and 13B presents cross section simplified views 1300 and 1350 of details in modifying the internal volume of the injectively-mixed backmixing reaction chamber 1202 of Figure 12.
  • an alternative view 1300 is presented for injectively-mixed backmixing reaction chamber 1202 in Figure 13A where a "hairbrush" distributor 1308 (further detailed in Figures 15A and 15B) for the oxygen- containing feed stream is depicted.
  • View 1300 of Figure 13A generally shows a bulkhead 1304 and optional blocking component 1302 in fully expanded or extended orientation to housing 1306.
  • Reactor view 1350 of Figure 13B generally shows bulkhead 1304 and optional blocking component 1302 in inserted orientation to housing 1306 to diminish the volume (and, in steady state operation, the space time) of the injectively-mixed backmixing reaction chamber respective to the volume (space-time) of view 1300.
  • Figure 14A presents a cross section simplified view 1400 of another alternative design for injectively-mixed backmixing reaction chamber 1202 of Figure 12.
  • a hemispherical head portion 1402 is profiled for the housing, with a comparably hemispherical profile in the inserted bulkhead.
  • Figure 14B shows a view 1450 depicting the injectively-mixed backmixing reaction chamber 1202 of Figure 12 with a modified internal volume from that shown in Figure 12.
  • Bulkhead 1232 and (optional) blocking component 1230 are depicted in inserted orientation to housing 1206 to diminish the volume (and, in steady state operation, the space time) of the injectively-mixed backmixing reaction chamber 1202 respective to the volume (space-time) of view 1200.
  • Figures 15A and 15B present aligned cross-sectional views 1500 and 1550 of the "hairbrush" fluid delivery insert 1308 for an alternative design for injectively- mixed backmixing reaction chamber 1202 of Figure 12.
  • Axis 1504 is aligned with axis 1220 in the preferred embodiment, with view 1500 showing "hairbrush" distributor 1308 detail respective to a plane perpendicular to axis 1504, and view 1550 showing "hairbrush" distributor 1308 detail respective to a plane parallel to axis 1504.
  • the oxygen-containing feed stream is input into internal flow space 1234 from a plurality of apertures (such as aperture 1502) disposed along the injectively-mixed backmixing reaction chamber axis in the essential centerline of the cylindrical surface of housing 1206 and in non-parallel orientation to the injectively-mixed backmixing reaction chamber axis 1220 when axis 1504 is essentially aligned with axis 1220.
  • a plurality of apertures such as aperture 1502
  • Figure 16 presents a cross section simplified view 1600 of internals for conical fluid delivery insert 1226 for delivering the oxygen-containing feed stream into the injectively-mixed backmixing reaction chamber 1202 of Figure 12.
  • the internal flow diverter is defined by a conical surface 1604 having an axis 1602.
  • a conical base 1614 is at one end of axis 1602, and apexial end 1612 (an end that, if the cone were extended, would ultimately converge to provide the apex of the cone) is at the other end of axis 1602.
  • axis 1602 is aligned with axis 1220 of injectively-mixed backmixing reaction chamber 1202 when conical diverter 1226 is disposed within cylindrical housing 1206 such that the backmixing reaction chamber output (passageway 1270) is more proximate to apexial end 1612 than to conical base 1614.
  • the oxygen-containing feed stream is input into inlet 1610 (from inlet 1224 of Figure 12) and then into internal flow space 1234 from a plurality of apertures 1608 disposed along injectively-mixed backmixing reaction chamber axis 1220 (axis 1602) and in non-parallel orientation to axis 1220.
  • Internal passageway 1606 fizidly conveys the oxygen-containing feed stream to the plurality of apertures 1608.
  • FIGS 17A and 17B present cross section simplified views of the interface baffle (1232/1230) details and positioning at the interface between injectively- mixed backmixing reaction chamber 1202 and tubular-flow reactor 1204 of the Figure 12 reactor system.
  • bulkhead 1702 has at least one aperture 1704 defining a passageway (see passageway 1270 in Figure 12) for fluid communication of an injectively-mixed backmixing reaction chamber product stream from injectively-mixed backmixing reaction chamber 1202 into tubular-flow reactor 1204.
  • Bulkhead 1702 (bulkhead 1232 in Figure 12) provides the passageway with at least one aperture 1704 having a cross-sectional area.
  • apertures 1704 In a flowing fluid, bulkhead 1702 with apertures 1704 defines a baffle for creating a pressure drop between injectively-mixed backmixing reaction chamber 1202 and tubular-flow reactor 1204 as the flowing fluid passes from injectively-mixed backmixing reaction chamber 1202 into tubular-flow reactor 1204.
  • apertures 1704 can be precisely sized in one embodiment so that no blocking component is needed; such an arrangement has fewer degrees of freedom for operation, but also is less complex from a sealing and construction standpoint.
  • a blocking component 1230 is deployed in an alternative embodiment where, as shown in view 1750 of Figure 17B, blocking component 1230 can be rotated to "block" a portion of the cross-sectional area of aperture 1704 where a portion of blocking component 1706 (blocking component 1230 of Figure 12) is shown constricting the passageway of aperture 1704 (note that view 1750 can be conceptualized as a view parallel to axis 1220 and toward injectively-mixed backmixing reaction chamber 1202 from tubular-flow reactor 1204) and thereby restricting the passageway.
  • bulkhead (1232/1702) has at least one aperture 1704 as a first aperture
  • blocking component (1230/1706) has at least one second aperture (1708).
  • first and second apertures preferably have essentially Identical dimensions
  • first aperture 1704 and second aperture 1708 are mutually disposed to positionally align, in one relative positioning of bulkhead (1232/1702) and blocking component (1230/1706), to define the passageway (1270) to have a cross- sectional area essentially equivalent to the cross-sectional area of the first aperture.
  • this can be appreciated by considering that the portion of aperture 1704 that is not blocked from passageway use by blocking component 1706 is also the portion of aperture 1708 that is not blocked from passageway use by bulkhead 1702.
  • FIG. 21 An alternative embodiment of the combination of bulkhead (1232/1702) and blocking component (1230/1706) that does not include use of rotation component 1218 is further discussed with respect to Figure 21.
  • bulkhead (1232/1702) is movable respective to stationary blocking component (1230/1706) where key slot 1710 provides an axially (with respect to axis 1220) slideable restraint against key 2110 ( Figure 21) for prohibiting rotation of blocking component (1230/1706).
  • bulkhead (1232/1702) is firmly attached to housing 1208, but housing 1208 further rotates about axis 1220 to achieve a variable passageway 1270 defined by aperture 1704 and aperture 1708.
  • Key 2110 is affixed to housing 1206 (details not shown), and aperture 1714 (Figure 17A) provides a non- resistive opening for key 2110 to pass into internal volume 1248 so that bulkhead (1232/1702) and blocking component (1230/1706) move axially (axis 1220) respective to inlet 1224 with blocking component 1230/1706 always restrained and bulkhead 1232/1702 always capable of rotation about axis 1220.
  • Ball bearings 1712 are used in preferred embodiments to augment smooth rotation of the movable component (either of bulkhead 1232/1702 or blocking component 1230/1706 depending upon their particular embodiment) against the non- movable component in the baffle system.
  • Figures 18A and 18B presents cross sectional simplified views 1800, 1850, and 1860 of details and positioning for the variable position quenching inlet 1274 for the Figure 12 reactor system.
  • Guide tube 1264 is shown in perpendicular cross- sectional in view 1800 respective to axis 1220 as tube cross-section 1802 having an elongated slot 1808 running along axis 1220.
  • the elongated slot is difficult to show in Figure 12, but it is depicted in Figures 18A and 18B as fully open passageway 1808 to convey the axial slot; quench tube 1804/1262 is shown with aperture 1806/1274 -- see inlet passageway 1274 in Figure 12 — to show that it is an opening having substantially less axial dimension than the axial dimension of slot 1808 of guide tube 1802/1264.
  • Tube 1804/1262 co-operates with guide tube 1802/1264 as shown in view 1850 to not convey quench into internal volume 1248 when aperture 1806 is rotated to block the passageway (1274) with the internal surface of guide tube 1802/1264.
  • tube 1804/1262 is axially slideable within guide tube 1802/1264 to reposition aperture 1806/1274 axially along axis 1220.
  • View 1860 shows rotation of radial alignment between tube 1804/1262 and guide tube 1802/1264 so that passageway/inlet 1274 is enabled.
  • apertures 1806 can be readily provided at different radial positions of tube 1804 to provide alternative quench patterns as a function of the radial orientation of tube 1804/1262 along axis 1220 in tubular-flow reactor 1204.
  • Figures 19A - 19C present a series of temperature profiles for the tubular-flow reactor of the Figure 12 reactor system in operation.
  • axis of abscissas 1904 and axis of ordinates 1906 are identical throughout Figures 19A, 19B, and 19C with axis of abscissas 1904 showing distance along axis 1220 of tubular-flow reactor 1204 and axis of ordinates 1906 depicting temperature within the reaction fluid of .tubular-flow reactor 1204.
  • Locus 1902 (Figure 19A) is a conceptualized depiction of a temperature profile for tubular-flow reactor 1204 without benefit of quenching.
  • Locus 1922 ( Figure 19B) is a conceptualized depiction of a temperature profile for tubular-flow reactor 1204 with benefit of quenching from location 1938 to essentially output 1260.
  • Locus 1932 (Figure 19B) is a conceptualized depiction of a temperature profile for tubular-flow reactor 1204 with benefit of quenching at only location 1938.
  • the afore- discussed kinetic series sub-reactions will vary in their activity depending upon the temperature profile along axis 1220 within tubular-flow reactor 1204. So, for instance, the product mix from tubular-flow reactor 1204 will be different for each of Loci 1902, 1922, and 1932 per their differentiated thermal profiles, commensurately differentiated energies, and commensurately differentiated kinetic activity for individual sub-reactions in the kinetic series sub-reaction set.
  • FIG. 20 presents a cross section simplified view 2000 of an alternative embodiment of a reactor system having an injectively-mixed backmixing reaction chamber in close coupling to a tubular-flow reactor.
  • the interface baffle assembly (bulkhead 1232 and blocking component 1230 assembly embodiments as described with respect to Figure 12 and the alternative key-restrained deployment embodiments of Figures 17A, 17B, and 21) is slideably movable and rotated during realtime operation of the reactor system of view 2000 to progress and/or retract away from input 2062 by use of a threaded seal and connection facilitated by male threading 2012 (male threading 2212 in Figures 21 and 22A - 22C).
  • male threading 2212 male threading 2212 in Figures 21 and 22A - 22C.
  • the majority of the injectively- mixed backmixing reaction chamber and the tubular-flow reactor share housing 2070, that is further threaded to provide female threading for co-operating with threading 2012/2212.
  • Figures 22A - 22C show further detail in this regard where Figure 22A shows tubular-flow reactor sleeve 2016 in fully progressed position, Figure 22B shows tubular-flow reactor sleeve 2016 in mid-point progression/retraction position, and Figure 22C shows tubular-flow reactor sleeve 2016 in fully retracted position.
  • the backmixing reaction chamber and tubular-flow reactor of the reactor system of view 2000 are aligned along axis 2014.
  • An alkane-containing gas feed stream enters through alkane gas input 2060 and the plurality of alkane gas input apertures as depicted.
  • An oxygen-containing gas feed stream enters through oxygen gas input 2062 and the hairbrush distributor as previously discussed with respect to Figures 15A and 15B.
  • a conical diverter/distributor ( Figure 16) is used for the oxygen-containing feed stream.
  • the tubular-flow reactor has tubular-flow reactor sleeve 2016 in slideably sealed interface at seal 2008 to housing 2004 and provides a fluid output into a relatively small space defined by housing 2004.
  • Housing 2004 has an axial depth sufficient to accommodate the full axial traverse enabled by threading 2012/2212 (see also Figures 22A- 22C).
  • Housing 2004 has an output for the reactor product stream at output 2020.
  • Cooling gas input 2002 receives the previously-described cooling gas stream into cooling gas space 2072 (defined between the internal surface of housing 2070 and the external surfaces of sleeve 2016 and blocking tube 2006).
  • the cooling gas stream then proceeds into the internal space of sleeve 2016 via spiral slot 2018, at a point where an axial slot (axial slot 2032 of perpendicular cross section view 2028 across axis 2014 in right-facing orientation at 2042 and of Figure 23) of blocking tube 2006 and spiral slot 2018 align to define a passageway (2302 of Figure 23) and also to thereby quenchably cool the internal space of tubular-flow reactor sleeve 2016.
  • Sleeve 2016 therefore co-operates closely with blocking tube 2006.
  • Sleeve 2016 is sealed to housing 2070 with slideable seal 2074 and thereby rotates to simultaneously process/regress respective to the injectively-mixed backmixing reaction chamber per threads 2012/2212 ( Figures 22A- 22C) 1 regulate the amount of quench delivered to a location within tubular-flow reactor sleeve 2016 (described with Figure 20 and further described with Figure 23), and modify the passageway cross-sectional area (fixed-key baffle assembly as previously discussed and further discussed in Figure 21).
  • sleeve 2016 is first rotated to position within the axial analog range for baffle positional procession/regression, then to position within the axial analog range for quenching, and finally to position within the axial analog range for the passageway cross-sectional area.
  • baffle positioning is anticipated to be a relatively strategic operational setting for a particular alkane-gas feed stream composition
  • realtime operational adjustments should relate more to the single-rotation quench and (1/6 rotation) baffle passageway positioning.
  • Perpendicular cross section view 2030 across axis 2014 in left-facing orientation at 2040 shows further detail in aperture positioning for inputting feeds from input 2060 and 2062 into the backmixing reaction chamber.
  • Figure 21 presents bulkhead/baffle details 2100 for the Figure 20 reactor system embodiment and also for the alternative embodiment of the interface between the injectively-mixed backmixing reaction chamber and the tubular-flow reactor of the Figure 12 reactor system embodiment as previously referenced with respect to Figures 17A and 17B.
  • Sleeve 2016 is reprised from Figure 20 with male threading 2012/2212.
  • blocking component 2108 is restrained from rotation by key 2110 (as inserted into slot 1710 ( Figure 17B) and bulkhead 2104 is in non-slideable attachment to sleeve 2016.
  • Ball bearings 2106 interface bulkhead 2104 (end of sleeve 2016) to blocking component 2108.
  • Bulkhead 2104 (sleeve 2016) rotates freely around key 2110 by virtue of non-restraining circular aperture 1714 ( Figure 17A).
  • Figures 22A - 22C show axial positioning details 2200, 2230, and 2260 for the interface between the injectively-mixed backmixing reaction chamber and the tubular-flow reactor of the Figure 20 reactor system embodiment.
  • Sleeve 2016 is reprised from Figure 20 with male threading 2012/2212.
  • Figure 23 shows further detail 2300 in the quenching inlet for the Figure 20 reactor system embodiment.
  • a vertical view of sleeve 2016 and blocking tube 2006 in alignment with the axis of entry for input 2002 ( Figure 20) is shown.
  • Sleeve 2016, blocking tube 2006, spiral slot 2018, and axial slot 2032 (view 2028 of Figure 20) are all reprised from Figure 20.
  • Location 2302 shows the alignment point of blocking tube 2006 and spiral slot 2018 for delivery of the quenching gas into sleeve 2016 to thereby quenchably cool the internal space of the tubular-flow reactor.
  • Figures 24A and 24B show axial view detail for the Figure 20 reactor system embodiment.
  • Figure 24A shows a right-facing view along axis 2014 (Figure 20) from the outside of the reactor system; inputs 2060 and 2062 are reprised from Figure 20.
  • Figure 24B shows perpendicular cross section view 2450 across axis 2014 in left- facing orientation at 2022 ( Figure 20); input 2002 is reprised from Figure 20 and apertures 1704/1706 are reprised from Figures 17A and 17B.
  • Figures 25A and 25B show views 2500 and 2550 of two tubular-flow reactor system embodiments having i ⁇ jectively-mixed entry zones (zone 2520 in both of Figures 25A & B), multi-position quenching, and multi-position temperature sensing.
  • Mixing zone 2520 in both Figure 25A and Figure 25B shows a symbolic conical distributor diverter 2502 with a full cone, highly similar to the conical diverter of Figure 16 and also of Figure 12.
  • System view 2500 of Figure 25A shows multiple thermocouples (such as thermocouple 2510) and multiple quench inlet ports (such as quench inlet port 2508) in housing 2512.
  • System view 2550 of Figure 25B shows variable position thermocouple 2504 and a variable position thermocouple quench inlet port 2506 sealing disposed within the internal space defined by housing 2514. Quenching and temperature measurement are therefore highly similar in Figures 12 and Figures 25B for the tubular-flow reactors of both of these embodiments.
  • the systems of both Figure 25A and Figure 25B are useful in 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 separating baffle assembly defining a clear interface between an injectively-mixed backmix reaction chamber and the tubular-reactor.
  • data from operation of a system of either of Figure 25A or Figure 25B when compared to data from operation of a system of either of Figure 12 or Figure 20, has value in indicating efficacy for settings respective to the baffled interface (bulkhead 1232/component 1230 in Figure 12 or the threaded baffling assembly of Figure 20).

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  • Chemical & Material Sciences (AREA)
  • Chemical Kinetics & Catalysis (AREA)
  • Organic Chemistry (AREA)
  • Dispersion Chemistry (AREA)
  • Organic Low-Molecular-Weight Compounds And Preparation Thereof (AREA)
  • Devices And Processes Conducted In The Presence Of Fluids And Solid Particles (AREA)

Abstract

L'invention concerne un procédé de production d'oxygénate d'alkyle (par ex., méthanol) par oxydation partielle d'alcane (méthane). Ledit procédé fait appel à une chambre de réaction à rétromélange mélangé par injection en communication fluidique avec un réacteur à écoulement tubulaire. Des radicaux libres alkyles sont induits dans la chambre de réaction à rétromélange avant d'être acheminés par l'intermédiaire d'un déflecteur à restriction de débit vers le réacteur à écoulement tubulaire. Le mélange par injection de flux d'alimentation agite la chambre de réaction à rétromélange. Dans un mode de réalisation, un déflecteur à position variable est déplacé axialement afin de modifier proportionnellement les volumes de la chambre de réaction à rétromélange et du réacteur à écoulement tubulaire. Dans un autre mode de réalisation, le réacteur à écoulement tubulaire est refroidi rapidement à l'aide d'une entrée de refroidissement rapide à position variable. Le procédé consiste également à condenser le flux de sortie du système de réaction dans un épurateur par condensation et à recycler une partie du flux de sortie épuré dans le système de réaction.
PCT/US2007/004297 2004-07-29 2007-02-19 Procédé d'oxygénation directe d'alcanes gazeux WO2007133310A2 (fr)

Priority Applications (7)

Application Number Priority Date Filing Date Title
CN200780017054.7A CN101443299B (zh) 2006-05-11 2007-02-19 用于直接氧化烷烃气体的方法
MX2008014389A MX2008014389A (es) 2006-05-11 2007-02-19 Metodo para la oxigenacion directa de gases de alcano.
BRPI0710431-6A BRPI0710431A2 (pt) 2006-05-11 2007-02-19 método para manufaturar pelo menos uma aquila oxigenda através da reação de oxidação parcial de alcano de uma corrente de alimentação de gás contendo alcano e de oxigênio de uma corrente de alimentação de gás contendo oxigênio
US11/685,852 US7578981B2 (en) 2004-07-29 2007-03-14 System for direct-oxygenation of alkane gases
US11/685,867 US7456327B2 (en) 2004-07-29 2007-03-14 Method for direct-oxygenation of alkane gases
US12/273,213 US7687669B2 (en) 2005-12-27 2008-11-18 Method for direct-oxygenation of alkane gases
US13/017,169 US8524175B2 (en) 2005-12-27 2011-01-31 Tandem reactor system having an injectively-mixed backmixing reaction chamber, tubular-reactor, and axially movable interface

Applications Claiming Priority (6)

Application Number Priority Date Filing Date Title
US11/432,692 2006-05-11
US11/432,692 US8293186B2 (en) 2004-07-29 2006-05-11 Method and apparatus for producing methanol
US11/446,371 2006-06-02
US11/446,371 US9180426B2 (en) 2004-07-29 2006-06-02 Scrubber for methanol production system
US11/526,824 US7910787B2 (en) 2004-07-29 2006-09-25 Method and system for methanol production
US11/526,824 2006-09-25

Related Parent Applications (2)

Application Number Title Priority Date Filing Date
US11/526,824 Continuation-In-Part US7910787B2 (en) 2004-07-29 2006-09-25 Method and system for methanol production
PCT/US2007/004185 Continuation-In-Part WO2007133309A2 (fr) 2004-07-29 2007-02-19 Système de réacteur en tandem comportant une chambre de réaction de rétromélange par mélange à injection, réacteur à écoulement tubulaire, et interface axialement mobile

Related Child Applications (1)

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PCT/US2007/004557 Continuation-In-Part WO2007133313A1 (fr) 2004-07-29 2007-02-19 Système d'oxygénation directe de gaz alcanes

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PCT/US2007/004185 WO2007133309A2 (fr) 2004-07-29 2007-02-19 Système de réacteur en tandem comportant une chambre de réaction de rétromélange par mélange à injection, réacteur à écoulement tubulaire, et interface axialement mobile

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Citations (1)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
US4618732A (en) * 1985-05-20 1986-10-21 Gesser Hyman D Direct conversion of natural gas to methanol by controlled oxidation

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Publication number Priority date Publication date Assignee Title
US2196188A (en) * 1935-12-24 1940-04-09 Ici Ltd Process of producing formaldehyde
DE2743113C3 (de) * 1977-09-24 1980-09-04 Chemische Werke Huels Ag, 4370 Marl Verfahren zur Herstellung von Gemischen aus Formaldehyd und Methanol durch partielle Oxidation von Methan
US4374288A (en) * 1980-12-17 1983-02-15 Scragg Robert L Electromagnetic process and apparatus for making methanol
GB8412386D0 (en) * 1984-05-15 1984-06-20 British Petroleum Co Plc Chemical process

Patent Citations (1)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
US4618732A (en) * 1985-05-20 1986-10-21 Gesser Hyman D Direct conversion of natural gas to methanol by controlled oxidation

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