U.S. patent application number 14/868911 was filed with the patent office on 2016-10-06 for advanced oxidative coupling of methane.
The applicant listed for this patent is Siluria Technologies, Inc.. Invention is credited to Andrew Aronson, Joel Cizeron, Suchia Duggal, Jarod McCormick, Guido Radaelli.
Application Number | 20160289143 14/868911 |
Document ID | / |
Family ID | 57004566 |
Filed Date | 2016-10-06 |
United States Patent
Application |
20160289143 |
Kind Code |
A1 |
Duggal; Suchia ; et
al. |
October 6, 2016 |
ADVANCED OXIDATIVE COUPLING OF METHANE
Abstract
The present disclosure provides a method for generating higher
hydrocarbon(s) from a stream comprising compounds with two or more
carbon atoms (C.sub.2+), comprising introducing methane and an
oxidant (e.g., O.sub.2) into an oxidative coupling of methane (OCM)
reactor that has been retrofitted into a system comprising an
ethylene-to-liquids (ETL) reactor. The OCM reactor reacts the
methane with the oxidant to generate a first product stream
comprising the C.sub.2+ compounds. The first product stream can
then be directed to a pressure swing adsorption (PSA) unit that
recovers at least a portion of the C.sub.2+ compounds from the
first product stream to yield a second product stream comprising
the at least the portion of the C.sub.2+ compounds. The second
product stream can then be directed to the ETL reactor. The higher
hydrocarbon(s) can then be generated from the at least the portion
of the C.sub.2+ compounds in the ETL reactor.
Inventors: |
Duggal; Suchia; (San Rafael,
CA) ; Radaelli; Guido; (South San Francisco, CA)
; McCormick; Jarod; (San Carlos, CA) ; Aronson;
Andrew; (San Bruno, CA) ; Cizeron; Joel;
(Redwood City, CA) |
|
Applicant: |
Name |
City |
State |
Country |
Type |
Siluria Technologies, Inc. |
San Francisco |
CA |
US |
|
|
Family ID: |
57004566 |
Appl. No.: |
14/868911 |
Filed: |
September 29, 2015 |
Related U.S. Patent Documents
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Application
Number |
Filing Date |
Patent Number |
|
|
62141789 |
Apr 1, 2015 |
|
|
|
Current U.S.
Class: |
1/1 |
Current CPC
Class: |
C07C 2/42 20130101; H01L
35/30 20130101; F01K 25/103 20130101; C07C 1/04 20130101; C07C 2/06
20130101; C07C 7/152 20130101; Y02E 60/36 20130101; F01K 5/00
20130101; C07C 4/02 20130101; Y02E 20/18 20130101; Y02P 20/129
20151101; F01K 23/067 20130101; C07C 2/82 20130101; C25B 1/04
20130101; C07C 1/12 20130101; C07C 2/82 20130101; C07C 11/04
20130101; C07C 7/152 20130101; C07C 11/04 20130101; C07C 1/04
20130101; C07C 9/04 20130101; C07C 1/12 20130101; C07C 9/04
20130101 |
International
Class: |
C07C 2/82 20060101
C07C002/82; C07C 1/12 20060101 C07C001/12; C07C 2/06 20060101
C07C002/06; H01L 35/30 20060101 H01L035/30; C07C 4/02 20060101
C07C004/02; C25B 1/04 20060101 C25B001/04; F01K 25/10 20060101
F01K025/10; F01K 23/06 20060101 F01K023/06; C07C 1/04 20060101
C07C001/04; C07C 2/42 20060101 C07C002/42 |
Claims
1. A method for generating higher hydrocarbon(s) from a stream
comprising compounds with two or more carbon atoms (C.sub.2+),
comprising: (a) introducing methane and an oxidant into an
oxidative coupling of methane (OCM) reactor that has been
retrofitted into a system comprising an ethylene-to-liquids (ETL)
reactor, wherein said OCM reactor reacts said methane with said
oxidant to generate a first product stream comprising said C.sub.2+
compounds; (b) directing said first product stream to a pressure
swing adsorption (PSA) unit that recovers at least a portion of
said C.sub.2+ compounds from said first product stream to yield a
second product stream comprising said at least said portion of said
C.sub.2+ compounds; (c) directing said second product stream to
said ETL reactor; and (d) generating said higher hydrocarbon(s)
from said at least said portion of said C.sub.2+ compounds in said
ETL reactor.
2. The method of claim 1, further comprising: recovering a light
stream comprising (i) hydrogen and (ii) carbon monoxide (CO) and/or
carbon dioxide (CO.sub.2) from said PSA unit and recycling said
light stream to said OCM reactor; directing at least a portion of
said light stream into a methanation unit that reacts said hydrogen
and said CO and/or CO.sub.2 to produce a methanation product stream
comprising methane; and directing said methanation product stream
into said OCM reactor.
3. The method of claim 1, further comprising recovering C.sub.2
and/or C.sub.3 compounds from said second product stream and
directing said C.sub.2 and/or C.sub.3 compounds to said OCM
reactor.
4. The method of claim 1, wherein said OCM reactor further
comprises a post-bed cracking (PBC) unit.
5. A method for generating compounds with two or more carbon atoms
(C.sub.2+ compounds), comprising: (a) directing oxygen (O.sub.2)
and methane (CH.sub.4) into an oxidative coupling of methane (OCM)
reactor that reacts said O.sub.2 and CH.sub.4 in an OCM process to
yield a product stream comprising (i) C.sub.2+ compounds including
ethylene (C.sub.2H.sub.4) and (ii) carbon monoxide (CO) and/or
carbon dioxide (CO.sub.2); and (b) directing said product stream
from said OCM reactor into a separations system that employs a
refrigeration unit having a refrigerant that includes methane from
said product stream, to enrich said C.sub.2+ compounds in said
product stream.
6. The method of claim 5, wherein said product stream is directed
into said separations system through one or more additional
units.
7. The method of claim 5, further comprising separating methane
from said product stream for use in said refrigeration unit.
8. The method of claim 5, further comprising directing CO and/or
CO.sub.2 from said product stream to a methanation reactor that
reacts said CO and/or CO.sub.2 to yield a methanation product
stream comprising methane.
9. The method of claim 8, further comprising directing at least a
portion of said methane in said methanation product stream to said
OCM reactor.
10. The method of claim 5, further comprising separating said
product stream into (i) an ethylene product stream comprising
ethylene and (ii) a C.sub.3+ product stream comprising compounds
with three or more carbon atoms (C.sub.3+ compounds).
11. The method of claim 5, further comprising directing ethane from
said product stream to said OCM reactor.
12. The method of claim 5, further comprising, prior to directing
said product stream into said separations system, compressing said
product stream.
13. A method for generating compounds with two or more carbon atoms
(C.sub.2+ compounds), comprising: (a) directing oxygen (O.sub.2)
and methane (CH.sub.4) into an oxidative coupling of methane (OCM)
reactor that reacts said O.sub.2 and CH.sub.4 in an OCM process to
yield a product stream comprising (i) C.sub.2+ compounds including
ethylene (C.sub.2H.sub.4) and (ii) carbon monoxide (CO) and/or
carbon dioxide (CO.sub.2); and (b) directing said product stream
from said OCM reactor into a separations system that employs a
complexation unit having a complexation catalyst that forms pi
complexes with said ethylene in said product stream, to enrich said
C.sub.2+ compounds in said product stream.
14. The method of claim 13, wherein said product stream is directed
into said separations system through one or more additional
units.
15. The method of claim 13, further comprising using said
complexation unit to remove one or more impurities from said
product stream, wherein said impurities are selected from the group
consisting of CO.sub.2, sulfur compounds, acetylenes, and
hydrogen.
16. The method of claim 13, wherein said complexation catalyst
includes one or more metals selected from the group consisting of
silver and copper.
17. The method of claim 13, further comprising directing CO and/or
CO.sub.2 from said product stream to a methanation reactor that
reacts said CO and/or CO.sub.2 to yield a methanation product
stream comprising methane.
18. The method of claim 17, further comprising directing said
methane in said methanation product stream to said OCM reactor.
19. The method of claim 13, further comprising separating said
product stream into (i) an ethylene product stream comprising
ethylene and (ii) a C.sub.3+ product stream comprising compounds
with three or more carbon atoms (C.sub.3+ compounds).
20. The method of claim 13, further comprising directing ethane
from said product stream to said OCM reactor.
21. The method of claim 13, further comprising, prior to directing
said product stream into said separations system, compressing said
product stream.
22. A method for generating compounds with two or more carbon atoms
(C.sub.2+ compounds), comprising: (a) directing oxygen (O.sub.2)
and methane (CH.sub.4) into an oxidative coupling of methane (OCM)
reactor that reacts said O.sub.2 and CH.sub.4 in an OCM process to
yield a product stream comprising (i) C.sub.2+ compounds including
ethylene (C.sub.2H.sub.4) and (ii) carbon dioxide (CO.sub.2); and
(b) directing said product stream from said OCM reactor into a
separations system that employs a CO.sub.2 separation unit to
separate said CO.sub.2 from said product stream, to enrich said
C.sub.2+ compounds in said product stream, which CO.sub.2
separation unit employs (i) sorbent or solvent separation of
CO.sub.2, (ii) membrane separation of CO.sub.2, or (iii) cryogenic
or low temperature separation of CO.sub.2 having an operating
temperature greater than a boiling point of methane and less than a
boiling point of CO.sub.2.
23. The method of claim 22, wherein said product stream is directed
into said separations system through one or more additional
units.
24. The method of claim 22, wherein said sorbent or solvent
separation of CO.sub.2 employs an amine based absorption system, a
Benfield process, diethanolamine, glycol dimethylether, propylene
carbonate, Sulfinol, a zeolite, or active carbon.
25.-31. (canceled)
32. The method of claim 22, wherein said CO.sub.2 separation system
comprises a membrane CO.sub.2 separation system.
33. The method of claim 22, wherein said membrane separation of
CO.sub.2 employs a polymeric membrane, metallic membrane, ceramic
membrane, poly ionic liquid membrane, supported ionic liquid
membrane, polyetherimide membrane, or hybrid membrane comprising a
membrane supporting a solvent or sorbent.
34.-39. (canceled)
40. The method of claim 22, further comprising directing said
CO.sub.2 from said product stream to a methanation reactor that
reacts said CO.sub.2 to yield a methanation product stream
comprising methane.
41. The method of claim 40, further comprising directing said
methane in said methanation product stream to said OCM reactor.
42. The method of claim 22, further comprising separating said
product stream into (i) an ethylene product stream comprising
ethylene and (ii) a C.sub.3+ product stream comprising compounds
with three or more carbon atoms (C.sub.3+ compounds).
43. The method of claim 22, further comprising directing ethane
from said product stream to said OCM reactor.
44. The method of claim 22, further comprising, prior to directing
said product stream into said separations unit, compressing said
product stream.
45. A method for generating compounds with two or more carbon atoms
(C.sub.2+ compounds), comprising: (a) directing water into an
electrolysis unit that electrolyzes said water to yield oxygen
(O.sub.2) and hydrogen (H.sub.2); (b) directing said O.sub.2 from
said electrolysis unit and methane (CH.sub.4) into an oxidative
coupling of methane (OCM) reactor that reacts said O.sub.2 and
CH.sub.4 in an OCM process to yield a product stream comprising (i)
C.sub.2+ compounds, including ethylene (C.sub.2H.sub.4) and (ii)
carbon monoxide (CO) and/or carbon dioxide (CO.sub.2); (c)
directing at least a portion of said CO and/or CO.sub.2 from said
product stream and said H.sub.2 from said electrolysis unit into a
methanation reactor that reacts said H.sub.2 and said CO and/or
CO.sub.2 to yield CH.sub.4; and (d) directing at least a portion of
said CH.sub.4 from said methanation reactor to said OCM
reactor.
46.-48. (canceled)
49. A method for generating compounds with two or more carbon atoms
(C.sub.2+ compounds), comprising: (a) directing oxygen (O.sub.2)
and methane (CH.sub.4) into an oxidative coupling of methane (OCM)
reactor that reacts said O.sub.2 and CH.sub.4 in an OCM process to
yield a product stream comprising (i) C.sub.2+ compounds including
ethylene (C.sub.2H.sub.4) and (ii) carbon dioxide (CO.sub.2); (b)
directing said product stream from said OCM reactor into a
separations system that employs a CO.sub.2 separation unit that
separates said CO.sub.2 from said product stream to enrich said
C.sub.2+ compounds in said product stream; and (c) directing at
least a portion of said CO.sub.2 separated in (b) to said OCM
reactor.
50. (canceled)
51. A method for generating compounds with two or more carbon atoms
(C.sub.2+ compounds), comprising: (a) directing oxygen (O.sub.2)
and methane (CH.sub.4) into an oxidative coupling of methane (OCM)
reactor that reacts said O.sub.2 and CH.sub.4 in an OCM process to
yield a product stream comprising C.sub.2+ compounds including
ethylene (C.sub.2H.sub.4) and heat; (b) using an evaporator to
transfer at least a portion of said heat from said product stream
to an organic working fluid in a closed fluid flow cycle as part of
an organic Rankine cycle (ORC) system, to evaporate said organic
working fluid, which closed fluid flow cycle includes said
evaporator, a turbine, a condenser, and a pump; (c) directing said
organic working fluid evaporated in (b) to said turbine to generate
power; (d) directing said organic working fluid from said turbine
to said condenser that condenses said organic working fluid; and
(e) directing said organic working fluid condensed in (d) to said
pump.
52. (canceled)
53. (canceled)
54. A method for generating compounds with two or more carbon atoms
(C.sub.2+ compounds), comprising: (a) directing oxygen (O.sub.2)
and methane (CH.sub.4) into an oxidative coupling of methane (OCM)
reactor that reacts said O.sub.2 and CH.sub.4 in an OCM process to
yield a product stream comprising (i) C.sub.2+ compounds including
ethylene (C.sub.2H.sub.4) and heat; (b) transferring at least a
portion of said heat from said product stream to a thermoelectric
power generator; and (c) with the aid of said heat, using said
thermoelectric power generator to generate power.
55. (canceled)
56. (canceled)
Description
CROSS-REFERENCE
[0001] This application claims priority to U.S. Provisional Patent
Application Ser. No. 62/141,789, filed Apr. 1, 2015, which is
entirely incorporated herein by reference.
BACKGROUND
[0002] The modern refining and petrochemical industry makes
extensive use of fractionation technology to produce and separate
various desirable compounds from crude oil. The conventional
fractionation technology is energy intensive and costly to install
and operate. Cryogenic distillation has been in use for over a
hundred years to separate and recover hydrocarbon products in
various refining and petrochemical industries. However, there is a
need for non-cryogenic separation methods and systems, particularly
for oxidative coupling of methane (OCM) processes.
SUMMARY
[0003] Aspects of the present disclosure provide processes for
recovering olefins from a stream containing mix of hydrocarbons by
utilizing techniques based the use of adsorbents. In some
embodiments, systems and methods enable the separation,
pre-separation, purification and/or recovery of hydrocarbons,
including, but not limited to, olefins, ethylene, propylene,
methane, and ethane, and CO.sub.2, from a multicomponent
hydrocarbon stream such as an effluent stream from an oxidative
coupling of methane (OCM) reactor or an ethylene-to-liquids (ETL)
reactor. The hydrocarbon stream can also be the feed to the OCM or
ETL reactor in certain cases. In certain cases, the feed to the ETL
reactor is the effluent from OCM reactor. In some cases, a
separation process utilizing adsorbents can be used to purify and
pre-treat existing hydrocarbon streams (such as refinery off-gases,
cracker off-gas, streams from NGL plants, and others), followed by
use of the resulting olefin rich stream (e.g., PSA tail gas) as the
ETL feed.
[0004] The present disclosure provides various improvements in OCM
and ETL processes, such as, without limitation, a separation and
pre-separation process to recover desired or predetermined
components from an OCM reactor effluent, CO.sub.2 recovery and
capture techniques, enhanced heat recovery methods to utilize the
OCM reaction heat more efficiently, and techniques and technologies
to further reduce the carbon footprint of the OCM process.
[0005] An aspect of the present disclosure provides a method for
generating higher hydrocarbon(s) from a stream comprising compounds
with two or more carbon atoms (C.sub.2+), comprising introducing
methane and an oxidant (e.g., O.sub.2) into an oxidative coupling
of methane (OCM) reactor that has been retrofitted into a system
comprising an ethylene-to-liquids (ETL) reactor. The OCM reactor
reacts the methane with the oxidant to generate a first product
stream comprising the C.sub.2+ compounds. The first product stream
can then be directed to a pressure swing adsorption (PSA) unit that
recovers at least a portion of the C.sub.2+ compounds from the
first product stream to yield a second product stream comprising
the at least the portion of the C.sub.2+ compounds. The second
product stream can then be directed to the ETL reactor. The higher
hydrocarbon(s) can then be generated from the at least the portion
of the C.sub.2+ compounds in the ETL reactor.
[0006] In some cases, the first product stream is directed to other
intermediate units before the PSA, such as a post-bed cracking
(PBC) unit that generates alkenes from alkanes. The alkenes can be
included in the first product stream, which can then be directed to
the PSA.
[0007] In an aspect, the present disclosure provides a method for
generating higher hydrocarbon(s) from a stream comprising compounds
with two or more carbon atoms (C.sub.2+), comprising: (a)
introducing methane and an oxidant into an oxidative coupling of
methane (OCM) reactor that has been retrofitted into a system
comprising an ethylene-to-liquids (ETL) reactor, where the OCM
reactor reacts the methane with the oxidant to generate a first
product stream comprising the C.sub.2+ compounds; (b) directing the
first product stream to a pressure swing adsorption (PSA) unit that
recovers at least a portion of the C.sub.2+ compounds from the
first product stream to yield a second product stream comprising
the at least the portion of the C.sub.2+ compounds; (c) directing
the second product stream to the ETL reactor; and (d) generating
the higher hydrocarbon(s) from the at least the portion of the
C.sub.2+ compounds in the ETL reactor.
[0008] In some embodiments, the method further comprises: (e)
recovering a light stream comprising (i) hydrogen and (ii) carbon
monoxide (CO) and/or carbon dioxide (CO.sub.2) from the PSA unit
and recycling the light stream to the OCM reactor; (f) directing at
least a portion of the light stream into a methanation unit that
reacts the hydrogen and the CO and/or CO.sub.2 to produce a
methanation product stream comprising methane; and (g) directing
the methanation product stream into the OCM reactor.
[0009] In some embodiments, the method further comprises recovering
C.sub.2 and/or C.sub.3 compounds from the second product stream and
directing the C.sub.2 and/or C.sub.3 compounds to the OCM reactor.
In some embodiments, the OCM reactor further comprises a post-bed
cracking (PBC) unit.
[0010] In another aspect, the present disclosure provides a method
for generating compounds with two or more carbon atoms (C.sub.2+
compounds), comprising: (a) directing oxygen (O.sub.2) and methane
(CH.sub.4) into an oxidative coupling of methane (OCM) reactor that
reacts the O.sub.2 and CH.sub.4 in an OCM process to yield a
product stream comprising (i) C.sub.2+ compounds including ethylene
(C.sub.2H.sub.4) and (ii) carbon monoxide (CO) and/or carbon
dioxide (CO.sub.2); and (b) directing the product stream from the
OCM reactor into a separations system that employs a refrigeration
unit having a refrigerant that includes methane from the product
stream, to enrich the C.sub.2+ compounds in the product stream.
[0011] In some embodiments, the product stream is directed into the
separations system through one or more additional units.
[0012] In some embodiments, the method further comprises separating
methane from the product stream for use in the refrigeration unit.
In some embodiments, the method further comprises directing CO
and/or CO.sub.2 from the product stream to a methanation reactor
that reacts the CO and/or CO.sub.2 to yield a methanation product
stream comprising methane. In some embodiments, the method further
comprises directing at least a portion of the methane in the
methanation product stream to the OCM reactor. In some embodiments,
the method further comprises separating the product stream into (i)
an ethylene product stream comprising ethylene and (ii) a C.sub.3+
product stream comprising compounds with three or more carbon atoms
(C.sub.3+ compounds). In some embodiments, the method further
comprises directing ethane from the product stream to the OCM
reactor. In some embodiments, the method further comprises prior to
directing the product stream into the separations system,
compressing the product stream.
[0013] In another aspect, the present disclosure provides a method
for generating compounds with two or more carbon atoms (C.sub.2+
compounds), comprising: (a) directing oxygen (O.sub.2) and methane
(CH.sub.4) into an oxidative coupling of methane (OCM) reactor that
reacts the O.sub.2 and CH.sub.4 in an OCM process to yield a
product stream comprising (i) C.sub.2+ compounds including ethylene
(C.sub.2H.sub.4) and (ii) carbon monoxide (CO) and/or carbon
dioxide (CO.sub.2); and (b) directing the product stream from the
OCM reactor into a separations system that employs a complexation
unit having a complexation catalyst that forms pi complexes with
the ethylene in the product stream, to enrich the C.sub.2+
compounds in the product stream.
[0014] In some embodiments, the product stream is directed into the
separations system through one or more additional units. In some
embodiments, the method further comprises using the complexation
unit to remove one or more impurities from the product stream,
where the impurities are selected from the group consisting of
CO.sub.2, sulfur compounds, acetylenes, and hydrogen. In some
embodiments, the complexation catalyst includes one or more metals
selected from the group consisting of silver and copper. In some
embodiments, the method further comprises directing CO and/or
CO.sub.2 from the product stream to a methanation reactor that
reacts the CO and/or CO.sub.2 to yield a methanation product stream
comprising methane. In some embodiments, the method further
comprises directing the methane in the methanation product stream
to the OCM reactor. In some embodiments, the method further
comprises separating the product stream into (i) an ethylene
product stream comprising ethylene and (ii) a C.sub.3+ product
stream comprising compounds with three or more carbon atoms
(C.sub.3+ compounds). In some embodiments, the method further
comprises directing ethane from the product stream to the OCM
reactor. In some embodiments, the method further comprises prior to
directing the product stream into the separations system,
compressing the product stream.
[0015] In another aspect, the present disclosure provides a method
for generating compounds with two or more carbon atoms (C.sub.2+
compounds), comprising: (a) directing oxygen (O.sub.2) and methane
(CH.sub.4) into an oxidative coupling of methane (OCM) reactor that
reacts the O.sub.2 and CH.sub.4 in an OCM process to yield a
product stream comprising (i) C.sub.2+ compounds including ethylene
(C.sub.2H.sub.4) and (ii) carbon dioxide (CO.sub.2); and (b)
directing the product stream from the OCM reactor into a
separations system that employs a CO.sub.2 separation unit to
separate the CO.sub.2 from the product stream, to enrich the
C.sub.2+ compounds in the product stream, which CO.sub.2 separation
unit employs (i) sorbent or solvent separation of CO.sub.2, (ii)
membrane separation of CO.sub.2, or (iii) cryogenic or low
temperature separation of CO.sub.2 having an operating temperature
greater than a boiling point of methane and less than a boiling
point of CO.sub.2.
[0016] In some embodiments, the product stream is directed into the
separations system through one or more additional units. In some
embodiments, the sorbent or solvent separation of CO.sub.2 employs
an amine based absoprtion system. In some embodiments, the sorbent
or solvent separation of CO.sub.2 employs a Benfield process. In
some embodiments, the sorbent or solvent separation of CO.sub.2
employs diethanolamine. In some embodiments, the sorbent or solvent
separation of CO.sub.2 employs glycol dimethylether. In some
embodiments, the sorbent or solvent separation of CO.sub.2 employs
propylene carbonate. In some embodiments, the sorbent or solvent
separation of CO.sub.2 employs Sulfinol.
[0017] In some embodiments, the sorbent or solvent separation of
CO.sub.2 employs a zeolite. In some embodiments, the sorbent or
solvent separation of CO.sub.2 employs active carbon. In some
embodiments, the CO.sub.2 separation system comprises a membrane
CO.sub.2 separation system. In some embodiments, the membrane
separation of CO.sub.2 employs a polymeric membrane. In some
embodiments, the membrane separation of CO.sub.2 employs a metallic
membrane. In some embodiments, the membrane separation of CO.sub.2
employs a ceramic membrane. In some embodiments, the membrane
separation of CO.sub.2 employs a hybrid membrane comprising a
membrane supporting a solvent or sorbent. In some embodiments, the
membrane separation of CO.sub.2 employs a poly ionic liquid
membrane. In some embodiments, the membrane separation of CO.sub.2
employs a supported ionic liquid membrane. In some embodiments, the
membrane separation of CO.sub.2 employs a polyetherimide
membrane.
[0018] In some embodiments, the method further comprises directing
the CO.sub.2 from the product stream to a methanation reactor that
reacts the CO.sub.2 to yield a methanation product stream
comprising methane. In some embodiments, the method further
comprises directing the methane in the methanation product stream
to the OCM reactor. In some embodiments, the method further
comprises separating the product stream into (i) an ethylene
product stream comprising ethylene and (ii) a C.sub.3+ product
stream comprising compounds with three or more carbon atoms
(C.sub.3+ compounds). In some embodiments, the method further
comprises directing ethane from the product stream to the OCM
reactor. In some embodiments, the method further comprises prior to
directing the product stream into the separations unit, compressing
the product stream.
[0019] In another aspect, the present disclosure provides a method
for generating compounds with two or more carbon atoms (C.sub.2+
compounds), comprising: (a) directing water into an electrolysis
unit that electrolyzes the water to yield oxygen (O.sub.2) and
hydrogen (H.sub.2); (b) directing the O.sub.2 from the electrolysis
unit and methane (CH.sub.4) into an oxidative coupling of methane
(OCM) reactor that reacts the O.sub.2 and CH.sub.4 in an OCM
process to yield a product stream comprising (i) C.sub.2+
compounds, including ethylene (C.sub.2H.sub.4) and (ii) carbon
monoxide (CO) and/or carbon dioxide (CO.sub.2); (c) directing at
least a portion of the CO and/or CO.sub.2 from the product stream
and the H.sub.2 from the electrolysis unit into a methanation
reactor that reacts the H.sub.2 and the CO and/or CO.sub.2 to yield
CH.sub.4; and (d) directing at least a portion of the CH.sub.4 from
the methanation reactor to the OCM reactor.
[0020] In some embodiments, the electrolysis unit comprises an
alkaline water electrolysis system. In some embodiments, the
electrolysis unit comprises a proton exchange membrane electrolysis
system. In some embodiments, the electrolysis unit comprises a
steam electrolysis system.
[0021] In another aspect, the present disclosure provides a method
for generating compounds with two or more carbon atoms (C.sub.2+
compounds), comprising: (a) directing oxygen (O.sub.2) and methane
(CH.sub.4) into an oxidative coupling of methane (OCM) reactor that
reacts the O.sub.2 and CH.sub.4 in an OCM process to yield a
product stream comprising (i) C.sub.2+ compounds including ethylene
(C.sub.2H.sub.4) and (ii) carbon dioxide (CO.sub.2); (b) directing
the product stream from the OCM reactor into a separations system
that employs a CO.sub.2 separation unit that separates the CO.sub.2
from the product stream to enrich the C.sub.2+ compounds in the
product stream; and (c) directing at least a portion of the
CO.sub.2 separated in (b) to the OCM reactor.
[0022] In some embodiments, the product stream is directed into the
separations system through one or more additional units.
[0023] In another aspect, the present disclosure provides a method
for generating compounds with two or more carbon atoms (C.sub.2+
compounds), comprising: (a) directing oxygen (O.sub.2) and methane
(CH.sub.4) into an oxidative coupling of methane (OCM) reactor that
reacts the O.sub.2 and CH.sub.4 in an OCM process to yield a
product stream comprising C.sub.2+ compounds including ethylene
(C.sub.2H.sub.4) and heat; (b) using an evaporator to transfer at
least a portion of the heat from the product stream to an organic
working fluid in a closed fluid flow cycle as part of an organic
Rankine cycle (ORC) system, to evaporate the organic working fluid,
which closed fluid flow cycle includes the evaporator, a turbine, a
condenser, and a pump; (c) directing the organic working fluid
evaporated in (b) to the turbine to generate power; (d) directing
the organic working fluid from the turbine to the condenser that
condenses the organic working fluid; and (e) directing the organic
working fluid condensed in (d) to the pump.
[0024] In some embodiments, the organic working fluid is selected
from the group consisting of hydrocarbons, silicon oils, and
perfluorocarbons. In some embodiments, a boiling point of the
organic working fluid is less than a boiling point of water.
[0025] In another aspect, the present disclosure provides a method
for generating compounds with two or more carbon atoms (C.sub.2+
compounds), comprising: (a) directing oxygen (O.sub.2) and methane
(CH.sub.4) into an oxidative coupling of methane (OCM) reactor that
reacts the O.sub.2 and CH.sub.4 in an OCM process to yield a
product stream comprising (i) C.sub.2+ compounds including ethylene
(C.sub.2H.sub.4) and heat; (b) transferring at least a portion of
the heat from the product stream to a thermoelectric power
generator; and (c) with the aid of the heat, using the
thermoelectric power generator to generate power.
[0026] In some embodiments, the thermoelectric generator comprises
a thin film thermoelectric module. In some embodiments, the
thermoelectric generator comprises a micro thermoelectric
module.
[0027] Additional aspects and advantages of the present disclosure
will become readily apparent to those skilled in this art from the
following detailed description, wherein only illustrative
embodiments of the present disclosure are shown and described. As
will be realized, the present disclosure is capable of other and
different embodiments, and its several details are capable of
modifications in various obvious respects, all without departing
from the disclosure. Accordingly, the drawings and description are
to be regarded as illustrative in nature, and not as
restrictive.
INCORPORATION BY REFERENCE
[0028] All publications, patents, and patent applications mentioned
in this specification are herein incorporated by reference to the
same extent as if each individual publication, patent, or patent
application was specifically and individually indicated to be
incorporated by reference.
BRIEF DESCRIPTION OF THE FIGURES
[0029] The novel features of the invention are set forth with
particularity in the appended claims. A better understanding of the
features and advantages of the present invention will be obtained
by reference to the following detailed description that sets forth
illustrative embodiments, in which the principles of the invention
are utilized, and the accompanying drawings or figures (also "FIG."
and "FIGs." herein), of which:
[0030] FIG. 1 shows a typical oxidative coupling of methane (OCM)
system with advanced separation;
[0031] FIG. 2 shows an OCM system with auto refrigeration (e.g.,
methane refrigeration);
[0032] FIG. 3 shows an exemplary OCM system with a silver
complexation ethylene recovery subsystem;
[0033] FIG. 4 shows an exemplary pressure swing adsoprtion (PSA)
system;
[0034] FIG. 5A shows a schematic of CO.sub.2 separation
methods;
[0035] FIG. 5B shows a schematic of CO.sub.2 separation
methods;
[0036] FIG. 5C shows a schematic of CO.sub.2 separation
methods;
[0037] FIG. 6 shows typical CO.sub.2 distillation system;
[0038] FIG. 7 shows a water electrolysis sub system;
[0039] FIG. 8 shows an OCM system with CO.sub.2 as a quench
medium;
[0040] FIG. 9 shows an organic Rankine cycle (ORC) subsystem;
[0041] FIG. 10 shows an exemplary typical OCM system;
[0042] FIG. 11 shows an exemplary OCM system with a single stage
PSA unit;
[0043] FIG. 12 shows an exemplary OCM system with a multi stage PSA
unit;
[0044] FIG. 13 shows an exemplary retrofit of OCM to a cracker,
with a single stage PSA unit;
[0045] FIG. 14 shows an exemplary retrofit of OCM to a cracker,
with a multi stage PSA unit;
[0046] FIG. 15 shows exemplary configurations of ethylene to
liquids (ETL) systems without PSA;
[0047] FIG. 16 shows exemplary configurations of ETL systems with
PSA;
[0048] FIG. 17 shows an exemplary PSA unit integrated with an
OCM-ETL system for a midstream application;
[0049] FIG. 18 shows an exemplary PSA unit integrated with an
OCM-ETL system in a natural gas liquids (NGL) application;
[0050] FIG. 19 shows an exemplary PSA unit integrated with an
OCM-ETL system for a refining application; and
[0051] FIG. 20 shows an exemplary alternate scheme for a PSA unit
integrated with an OCM-ETL system for a refining application.
DETAILED DESCRIPTION
[0052] While various embodiments of the invention have been shown
and described herein, it will be obvious to those skilled in the
art that such embodiments are provided by way of example only.
Numerous variations, changes, and substitutions may occur to those
skilled in the art without departing from the invention. It should
be understood that various alternatives to the embodiments of the
invention described herein may be employed.
[0053] The term "higher hydrocarbon," as used herein, generally
refers to a higher molecular weight and/or higher chain
hydrocarbon. A higher hydrocarbon can have a higher molecular
weight and/or carbon content that is higher or larger relative to
starting material in a given process (e.g., OCM or ETL). A higher
hydrocarbon can be a higher molecular weight and/or chain
hydrocarbon product that is generated in an OCM or ETL process. For
example, ethylene is a higher hydrocarbon product relative to
methane in an OCM process. As another example, a C.sub.3+
hydrocarbon is a higher hydrocarbon relative to ethylene in an ETL
process. As another example, a C.sub.5+ hydrocarbon is a higher
hydrocarbon relative to ethylene in an ETL process. In some cases,
a higher hydrocarbon is a higher molecular weight hydrocarbon.
[0054] The term "OCM process," as used herein, generally refers to
a process that employs or substantially employs an oxidative
coupling of methane (OCM) reaction. An OCM reaction can include the
oxidation of methane to a higher hydrocarbon and water, and
involves an exothermic reaction. In an OCM reaction, methane can be
partially oxidized and coupled to form one or more C.sub.2+
compounds, such as ethylene. In an example, an OCM reaction is
2CH.sub.4+O.sub.2.fwdarw.C.sub.2H.sub.4+2H.sub.2O. An OCM reaction
can yield C.sub.2+ compounds. An OCM reaction can be facilitated by
a catalyst, such as a heterogeneous catalyst. Additional
by-products of OCM reactions can include CO, CO.sub.2, H.sub.2, as
well as hydrocarbons, such as, for example, ethane, propane,
propene, butane, butene, and the like.
[0055] The term "non-OCM process," as used herein, generally refers
to a process that does not employ or substantially employ an
oxidative coupling of methane reaction. Examples of processes that
may be non-OCM processes include non-OCM hydrocarbon processes,
such as, for example, non-OCM processes employed in hydrocarbon
processing in oil refineries, a natural gas liquids separations
processes, steam cracking of ethane, steam cracking or naphtha,
Fischer-Tropsch processes, and the like.
[0056] The terms "C.sub.2+" and "C.sub.2+ compound," as used
herein, generally refer to a compound comprising two or more carbon
atoms. For example, C.sub.2+ compounds include, without limitation,
alkanes, alkenes, alkynes and aromatics containing two or more
carbon atoms. C.sub.2+ compounds can include aldehydes, ketones,
esters and carboxylic acids. Examples of C.sub.2+ compounds include
ethane, ethene, acetylene, propane, propene, butane, and
butene.
[0057] The term "non-C.sub.2+ impurities," as used herein,
generally refers to material that does not include C.sub.2+
compounds. Examples of non-C.sub.2+ impurities, which may be found
in certain OCM reaction product streams, include nitrogen
(N.sub.2), oxygen (O.sub.2), water (H.sub.2O), argon (Ar), hydrogen
(H.sub.2) carbon monoxide (CO), carbon dioxide (CO.sub.2) and
methane (CH.sub.4).
[0058] The term "small scale," as used herein, generally refers to
a system that generates less than or equal to about 250 kilotons
per annum (KTA) of a given product, such as an olefin (e.g.,
ethylene).
[0059] The term "world scale," as used herein, generally refers to
a system that generates greater than about 250 KTA of a given
product, such as an olefin (e.g., ethylene). In some examples, a
world scale olefin system generates at least about 1000, 1100,
1200, 1300, 1400, 1500, or 1600 KTA of an olefin.
[0060] The term "item of value," as used herein, generally refers
to money, credit, a good or commodity (e.g., hydrocarbon). An item
of value can be traded for another item of value.
[0061] The term "carbon efficiency," as used herein, generally
refers to the ratio of the number of moles of carbon present in all
process input streams (in some cases including all hydrocarbon
feedstocks, such as, e.g., natural gas and ethane and fuel streams)
to the number of moles of carbon present in all commercially (or
industrially) usable or marketable products of the process. Such
products can include hydrocarbons that can be employed for various
downstream uses, such as petrochemical or for use as commodity
chemicals. Such products can exclude CO and CO.sub.2. The products
of the process can be marketable products, such as C.sub.2+
hydrocarbon products containing at least about 99% C.sub.2+
hydrocarbons and all sales gas or pipeline gas products containing
at least about 90% methane. Process input streams can include input
streams providing power for the operation of the process. In some
cases, power for the operation of the process can be provided by
heat liberated by an OCM reaction. In some cases, the systems or
methods of the present disclosure have a carbon efficiency of at
least about 50%, at least about 55%, at least about 60%, at least
about 65%, at least about 70%, at least about 75%, at least about
80%, at least about 85%, or at least about 90%. In some cases, the
systems or methods of the present disclosure have a carbon
efficiency of between about 50% and about 85%, between about 55%
and about 80%, between about 60% and about 80%, between about 65%
and about 85%, between about 65% and about 80%, or between about
70% and about 80%.
[0062] The term "C.sub.2+ selectivity," as used herein, generally
refers to the percentage of the moles of methane that are converted
into C.sub.2+ compounds.
[0063] The term "specific oxygen consumption," as used herein,
generally refers to the mass (or weight) of oxygen consumed by a
process divided by the mass of C.sub.2+ compounds produced by the
process.
[0064] The term "specific CO.sub.2 emission," as used herein,
generally refers to the mass of CO.sub.2 emitted from the process
divided by the mass of C.sub.2+ compounds produced by the
process.
Separations
[0065] Various non-cryogenic separation techniques have been
increasingly employed for gas separations, purifications and
recovery of hydrocarbons. Membrane based processes and adsorbents
have been intensively studied for large scale applications for
olefins recovery. Since the development of synthetic adsorbents and
pressure swing adsorption (PSA) cycles, adsorption has been playing
an increasingly important role in gas separation and
purification.
[0066] PSA technology can be used in a large variety of
applications: Hydrogen purification, air separation, CO.sub.2
removal, noble gases purification, methane upgrading, n-iso
paraffin separation and so forth. While new applications for gas
separations by adsorption are continually being developed, the most
important applications have been air separation (for production of
O.sub.2 and N.sub.2) and hydrogen separation (from fuel gas).
Approximately 20% of O.sub.2 and N.sub.2 are currently produced by
PSA. The increasing industrial applications for adsorption have
stimulated a growing interest in research and new applications.
[0067] Processes of the present disclosure can employ a variety of
different separations techniques, alone or in combination. For
example, OCM processes can employ amine and caustic systems for
CO.sub.2 removal, molecular sieve guard beds for water removal, and
cryogenic distillation or other separation techniques for recovery
and purification of hydrocarbon components. Cryogenic separation
can refer to separations using temperature levels below 120 K or
about -153.degree. C. Other techniques include Selexol.TM. and
Rectisol.TM. processes for CO.sub.2 removal.
[0068] OCM product effluent can comprise a mixture of hydrocarbons
including but not limited to methane, ethane, ethylene, propane,
propylene, butanes, butenes, and higher hydrocarbons. OCM product
effluent can also comprise varying amounts of other components such
as H.sub.2, N.sub.2, CO, CO.sub.2 and H.sub.2O. The product of an
OCM reaction can include ethylene. The ethylene product can be
polymer grade, refinery grade or chemical grade. Depending on the
purity level required, different separation and/or purification
techniques can be employed with the OCM process. To recover high
purity ethylene, separation methods such as those discussed herein
can be used to remove a wide range of components.
[0069] Advantages of the advanced OCM processes described herein
can include reducing the cost, reducing the number of unit
operations ("units") used, and hence improving the overall process
for producing high purity polymer grade ethylene. Overall
conversion and carbon efficiency can also be improved. The
separation methods disclosed herein can also improve the overall
conversion and carbon efficiency.
[0070] The different separation and purification techniques
discussed herein can be used to separate the OCM product effluent
(e.g., process gas) into a plurality of streams, including but not
limited to a first stream comprising methane, hydrogen, carbon
monoxide and other lighter inerts and a second stream comprising
ethane, ethylene, propylene, and higher hydrocarbons. Separation
systems or subsystems employed can include those discussed herein,
such as a cryogenic demethanizer, a membrane separation system, or
a PSA based system.
[0071] The separation techniques discussed herein can be employed
to remove CO.sub.2, such as from an OCM product effluent stream.
One or more separations techniques can be used to remove CO.sub.2
including but not limited to absorption, adsorption, CO.sub.2
distillation, and membrane separation. The separation technique can
be non-cryogenic.
[0072] FIG. 1 shows a block flow diagram for an exemplary OCM
process. Oxygen 110 and methane 121 can be fed into an OCM reactor
101 for conversion into higher hydrocarbon compounds including
ethylene. The OCM product stream 111 can be directed to a
compressor 102, and the compressed product stream 112 can be fed
into a separations system 103. The separations system can include
pretreatment units 104, such as impurity and CO.sub.2 removal
units, as well as separations units 105, such as cryogenic,
non-cryogenic, complexation, membrane, and other separations units.
The separations system can be a combination of more than one
separation techniques, such as those discussed in this application.
The separation system can replace CO.sub.2 removal, moisture
removal, and cryogenic separation systems of existing OCM process
systems. The compressor system may not be required for some types
of separation processes. From the separations system, CO.sub.2 can
be vented 113, ethane 114 can be recovered, for example for
recycling to the OCM reactor, ethylene product 115 can be
recovered, and C.sub.3+ products 116 can be recovered.
Additionally, CO.sub.2 117 and methane 118 can be directed from the
separations system into a methanation unit 106. The methanation
unit can produce methane from the CO.sub.2, for recycling 119 back
to the OCM reactor. Additional methane 120 can be added to the OCM
reactor supply stream 121.
Auto Refrigeration
[0073] OCM process systems can use refrigeration subsystems to
condense overhead vapors, for example from a demethanizer, a
deethanizer, and/or a C.sub.2 splitter. The temperatures employed
can be in the range from about 12.degree. C. to about -100.degree.
C. These low temperatures can be achieved through the use of
multiple refrigeration systems, such as ethylene refrigeration and
propylene refrigeration systems, to provide different levels of
refrigeration. These can be similar to those employed in existing
steam crackers.
[0074] Alternatively, an open loop methane refrigeration system can
be employed to provide refrigeration for a demethanizer OCM product
effluent can comprise methane as the major component, for example
at a concentration of at least about 50 mol %, 60 mol %, 70 mol %,
80 mol %, or 90 mol %. The demethanizer can have the lowest
temperature requirements in the entire separations unit. Use of
methane refrigeration (e.g., auto-refrigeration) can provide
benefits such as elimination of the need for an additional
refrigeration system (e.g., new) for any added capacity. For
grassroots or greenfield OCM applications, this can considerably
reduce refrigeration compressor sizes needed. In some cases, an
entire refrigeration system can be eliminated. FIG. 2 shows a block
flow diagram for an exemplary open loop methane refrigeration
system, such as can be used in gas processing plants and steam
crackers to produce chilling for condensing overhead vapors from a
demethanizer Most elements of FIG. 2 correspond to the description
in FIG. 1; the separations unit 205 can include an open loop
methane refrigeration system to provide cooling for the
separations. The system can be combined with a single or multiple
stage (e.g., two-stage) expansion system (e.g., Joule Thompson) to
chill the incoming feed. In certain cases, multiple separate
lighter products are recovered, such as a light H.sub.2-rich
stream, a low pressure methane rich stream, and a high pressure
methane rich stream.
Mixed Refrigeration
[0075] Another alternative to ethylene and propylene refrigeration
subsystems is the use of a mixed refrigeration system. The mixed
refrigerant can be, for example, a mix of methane, ethylene and
propylene. The mixed refrigerant can be a mix of ethane and
propane. A wide range of possible mixed refrigerants can be
employed, and can be selected based on, for example, the
availability of certain components and the degree of refrigeration
required. A mixed refrigerant system can provide advantages for use
with an OCM reactor system, including the use of only one
refrigeration sub system. Rather than two refrigeration systems
each comprising multiple stages of refrigerant compressor,
associated vessels, exchangers, and other components, the process
can use a single refrigeration system. This can substantially
reduce capital cost. This can also reduce equipment count, which
can be a benefit especially for OCM retrofits at places where plot
space may be a concern.
Pi Complexation
[0076] Pi complexation techniques can be used to separate alkenes
from alkanes. Some metal ions complex selectively with unsaturated
organic compounds. Some of these complexes are reversible while
others are irreversible. For example, aqueous silver salt in
solution forms reversible complexes with olefins, and forms
irreversible complexes with acetylenes. This property can be
employed in an OCM process to recover ethylene and propylene from
OCM reactor effluent.
[0077] As shown in FIG. 3, separation of ethylene and/or propylene
by metal complexation can be divided into three major sections:
absorption, purification or venting of impurities, and desorption.
An exemplary process is provided for separation of ethylene and/or
propylene from a purified multi-component gas stream from the OCM
reactor. FIG. 3 shows a process for purifying a stream containing
ethylene using an aqueous silver nitrate solution. Metal
complexation (e.g., silver or cuprous ion complexation) can be used
to separate ethylene and/or propylene from a purified
multi-component gas stream produced via OCM comprising C.sub.2
compounds, C.sub.3 compounds, and lighter components such as
hydrogen and nitrogen. First, the multi-component gas stream 310
can be introduced into an absorber 301 with aqueous silver salt
solution, such that the ethylene and/or propylene undergo
absorption or complexing with the silver metal ions, and such that
trace acetylenes react with the silver metal ions. Vent gas 311 can
be removed from the absorber. Then, the silver salt solution stream
312 can be vented 313 in a vent column 302 at reduced pressure to
remove any dissolved low molecular weight components. Then, the
resulting silver salt solution stream can be treated in a stripper
303 to separate the absorbed or complexed ethylene and/or propylene
from the silver salt solution, and further treated in a treatment
unit 304 to release the trace acetylenes. Purified ethylene 316 can
be recovered, and some product can be recycled 317. The aqueous
silver salt stream 318 can then be recycled to the first step, in
some cases after regeneration in a regeneration unit 305 with
AgMnO.sub.4 320. MnO.sub.2 321 can be removed from the regeneration
unit. H.sub.2O.sub.2 319 can be added to the solvent stream being
returned to the absorber.
[0078] Useful adsorbents include but are not limited to metal
compounds, such as silver or copper, supported on high surface area
carriers with a plurality of pores. These adsorbents can be used in
pressure swing adsorption or temperature swing adsorption
processes. When operating pressure and/or temperature is changed,
the silver or copper compound can release the alkene-rich component
from the adsorbent. These adsorbents can be very effective for
selective adsorption of alkenes such as ethylene, propylene, and
mixtures of these from gaseous mixtures.
[0079] When a gaseous component solubilizes in a liquid and
complexes with its ions, the loading of the gas can be affected by
its partial pressure and the temperature and the concentration of
the complexing ions in the solution. Therefore, by changing the
physical conditions separately or collectively, the active gaseous
component can either be formed into or out of the solution.
Adjusting or swinging one or more physical parameters can be used
to carry out an ethylene or propylene separation using an aqueous
silver nitrate solution. Purification or venting of impurities can
result in a product stream that is free or substantially free of
impurities including but not limited to CO.sub.2, sulfur compounds,
acetylenes, and hydrogen. Acetylene and hydrogen can cause
operational problems and so the process gas can be treated to bring
the concentration of such impurities to within an acceptable
limit.
[0080] Metal complexation can be used in combination with other
processes, such as membrane based processes.
Membranes
[0081] Membranes can be used to perform a variety of separations,
such as separations of olefins and paraffins, or separations of
CO.sub.2. A membrane can be essentially a barrier that separates
two phases and restricts transport of various chemicals in a
selective manner. Polymer membranes can be used to separate
mixtures such as propylene/propane mixtures and ethylene/butene
mixtures. Separations in polymeric membranes are dependent on the
solubility and diffusion of the species through the membrane. While
zeolite-based separations are predominantly depended on molecular
size differences, the differing permeation of olefins through a
polymeric membrane can be largely attributed to differences in
solubility, which can depend on the critical temperature and the
kinetic diameter. Membrane separations can be employed even when
there are small molecular size differences.
[0082] The OCM process can utilize a membrane based separation
process to further enhance the efficiency and energy consumption of
the process. Cryogenic distillation can be used for the separation
of alkenes, but is highly energy intensive. Membrane based
separations can be used for a variety of purposes in the context of
an OCM process, such as to separate and purify ethylene product
from OCM reactor effluent, to separate a stream rich in CO.sub.2,
to separate a stream containing lighter hydrocarbons and inerts, or
to separate C.sub.2 compounds from C.sub.1 and lighter
compounds.
[0083] Membranes can include but are not limited to isotropic
membranes, anisotropic membranes, and electrically charged
membranes. A membrane can be a ceramic membrane, a metal membrane,
or a liquid membrane. An isotropic membrane can be a microporous
membrane or a non-porous dense membrane. Membranes can be used for
separations including but not limited to CO.sub.2 separation,
paraffin-olefin separation, or selective recovery of pure ethylene
from the OCM reactor effluent. Polymer derived carbon molecular
sieve membranes can be used to separate paraffins from olefins.
These membranes can be used, for example, to separate ethylene from
a mix of methane and ethane.
[0084] Membrane separations can be used in combination with other
types of separation and purification subsystems to remove other
impurities such as acid gases, hydrogen, and nitrogen.
[0085] Transport through a membrane can take place when a driving
force is applied to the components in the feed. A driving force can
be a pressure differential or a concentration (activity) gradient
across the membrane. Membrane based separation techniques can be
used in an OCM process by applying either of the above mentioned
driving forces. A membrane based separation can also be a component
of a hybrid separation set-up, such as a membrane and an absorption
system (e.g., a membrane contactor) or a membrane in a pressure
swing adsorption (PSA) or a temperature swing adsorption (TSA)
system.
[0086] An OCM reactor can employ membranes as a part of the reactor
system to effectively separate the ethylene product within the
reactor system itself. A section of the reactor can include
membranes that aid in recovering the ethylene product, with a
methane rich stream being recycled to a methanation system and
eventually to the OCM reactor. Such a system can also use advanced
heat recovery or quench methods so as to facilitate the use of
membranes.
Pressure Swing Adsorption (PSA) and Adsorption Technology
[0087] Cryogenic separation (e.g., distillation) can be used for
the recovery of ethylene, propylene, and other components from
olefin plants, refinery gas streams, and other sources. These
separations can be difficult to accomplish because of the close
relative volatilities, and can have significant temperature and
pressure requirements for operation. The ethane/ethylene
distillation can be performed at about -25.degree. C. and 320
pounds per square inch gauge (psig) in a column containing over 100
trays. Distillation of propane and propylene can be performed at
about -30.degree. C. and 30 psig. These can be some of the most
energy intensive distillations in the chemical and petrochemical
industry. In general, the use of distillation towers to separate
recover and purify components is an energy intensive process.
[0088] The present disclosure provides the use of adsorbents that
can achieve separation and purification of olefin rich streams. In
particular, the present disclosure applies the use of PSA-based
adsorbent systems to separate, purify, and recover olefins like
ethylene and propylene from streams containing one or more
impurities such as methane, hydrogen, carbon monoxide, carbon
dioxide, ethane, or others. The streams, or parts of the streams,
can be generated via an OCM process, an ETL process, or
combinations thereof. The streams can be final product streams
where PSA is used to recover and purify the final product. The
streams can be intermediate streams which are purified prior to use
as a feed in a subsequent process, such as an ETL process, an
ethylene cracker (steam cracker), a refining unit, a fuel gas
system, a natural gas recovery plant or any other product
fractionation or product treatment unit.
Pressure Swing Adsorption (PSA)
[0089] A pressure swing adsorption (PSA) process cycle is one in
which desorption takes place at a different (e.g., lower) pressure
than the adsorption pressure. Reduction of pressure can be used to
shift the adsorption equilibrium and affect regeneration of the
adsorbent. Low pressure may not be as effective as temperature
elevation in totally reversing adsorption, unless very high feed to
purge pressure ratios are applied. Therefore, most PSA cycles are
characterized by high residual loadings and thus low operating
loadings. These low capacities at high concentration require that
cycle times be short for reasonably sized beds (e.g., seconds to
minutes). These short cycle times are attainable because particles
of adsorbent respond quickly to changes in pressure. Major uses for
PSA processes include purification as well as applications where
contaminants are present at high concentrations.
[0090] As shown in FIG. 4, the PSA system can comprise two fixed
bed adsorbers 401 and 402 undergoing a cyclic operation of four
steps--adsorption, blowdown, purge, and pressurization. The PSA
system can receive a feed 410 and produce a product stream 411,
with a PSA off gas stream 412. For improving the performance of the
basic Skarstrom.TM. cycle (FIG. 4), additional operation steps can
be employed such as pressure equalization, product pressurization,
and co-current depressurization. Besides these steps, the number of
beds can be modified to achieve the optimal operation and multi-bed
processes can be used in commercial applications like hydrogen
recovery. Similarly, a TSA system can be used where a swing in
temperature causes the sorption and desorption.
[0091] PSA cycles are used primarily for purification of wet gases
and of hydrogen. High pressure hydrogen employed in processes such
as hydrogenation, hydrocracking, and ammonia and methanol
production can be produced by PSA beds compounded of activated
carbon, zeolites and carbon molecular sieves. Other exemplary
applications include: air separation, methane enrichment,
iso/normal separations, and recovery of CO and CO.sub.2.
Adsorbents
[0092] Adsorbents can be natural or synthetic materials, such as
those having amorphous or microcrystalline structure. Exemplary
adsorbents useful for large scale operation include but are not
limited to activated carbon, molecular sieves, silica gels, and
activated alumina. Other useful adsorbents include pi complexation
sorbents, silver and copper complexation adsorbents, zeolites,
synthetic zeolites, mesoporous materials, activated carbons, high
surface area coordination polymers, molecular sieves, carbon
molecular sieves (CMS), silica gels, MCM, activated alumina, carbon
nanotubes, pillared clays, and polymeric resins.
[0093] For systems where the incoming stream is a multi-component
mixture of gases and the number of compounds to be separated cannot
be removed by a single adsorbent, different layers of adsorbents
can be used. For example, hydrogen purification from a methane
stream in a reforming operation, where H.sub.2 is contaminated with
H.sub.2O, CO.sub.2, CO, and unconverted CH.sub.4, can employ
activated carbon to remove H.sub.2O and CO.sub.2 in combination
with additional layers of different adsorbents used to increase the
loading of CO.
[0094] Zeolites, molecular sieves, and carbon molecular sieves
(CMS) can be used for most industrial separations employing PSA.
Inorganic materials, like special kinds of titanosilicates, can be
used for kinetic separations.
[0095] For systems specifically configured to separate
ethane/ethylene and propane/propylene, exemplary types of
adsorbents include zeolites/molecular sieves and pi complexation
sorbents. Zeolites/molecular sieves can be used for kinetic
separation, such as separation based on higher diffusivity of
olefins over that of paraffins. The use of 4 A zeolite is one such
example. Pi complexation sorbents, such as AgNO.sub.3/SiO.sub.2,
can give excellent results as compared to 4 A zeolite. PSA units as
discussed herein can employ a range of different sorbents,
including but not limited to a zeolite/molecular sieve sorbent, a
pi complexation based sorbent, a carbon molecular sieve sorbent or
any other form of activated carbon, carbon nanotubes, polymeric
resin based sorbents, or other sorbents.
[0096] Adsorbents can be selected based on a number of different
criteria. Adsorbent selection criteria can include capacity for the
target components (e.g., affinity for the desired components to be
separated from the multi-component feed stream), selectivity
between components competing for same adsorption sites,
regenerability of the adsorbent, (e.g., the ability of the
adsorbent to release the adsorbed target components at a reasonable
pressure rate of gas diffusion into the adsorbent--this can also
affect the size of the bead that is chosen and consequently the
pressure drop across the bed; an insufficient diffusion rate can
require smaller diameter beads that can result in higher pressure
drop and hence increased operating costs), and chemical
compatibility (e.g., selecting an adsorbent resistant to chemical
attack that may poison or destroy the adsorbent, such as liquid
hydrocarbons causing physical breakdown of the adsorbent resulting
in loss of efficiency and back pressure).
CO.sub.2 Separation
[0097] There are many technologies available for CO.sub.2 capture,
such as from flue gases, natural gas, or from any process gas rich
in CO.sub.2. Various processes for post-combustion or
pre-combustion capture can be used reduce CO.sub.2 emissions. FIG.
5A, FIG. 5B, and FIG. 5C show exemplary schematics of different
separation methods available to separate CO.sub.2 from a process
gas or a flue gas.
[0098] OCM processes can utilize an amine based absorption system
for CO.sub.2 removal, which can be followed by use of a caustic
scrubber to obtain high degree of separation. The amine system is
prone to corrosion, solvent degradation, and above all, has high
energy requirements. Separations with sorbents and/or solvents can
involve placing the CO.sub.2 containing gas in intimate contact
with a liquid absorbent or a solid sorbent that is capable of
capturing the CO.sub.2. As shown in FIG. 5A, a stream with CO.sub.2
510 can be directed into a capture vessel 501, where it contacts
sorbent which captures CO.sub.2 from the stream. The stream, with
reduced or removed CO.sub.2, can then exit 511 the vessel. Sorbent
512 loaded with captured CO.sub.2 can be transferred to a sorbent
regeneration vessel 502 where it releases the CO.sub.2 after being
heated (e.g., with the use of energy 513), after a pressure
decrease, or after any other change in the conditions around the
sorbent, thereby regenerating the sorbent. Spent sorbent 515 and
CO.sub.2 516 can be removed from the vessel, and make up sorbent
513 can be added. After the regeneration step the sorbent can be
sent back to capture more CO.sub.2 in a cyclic process. The sorbent
can be a solid. Solid sorbent can remain in a single vessel rather
than being cycled between vessels; sorption and regeneration can be
achieved by cyclic changes (e.g., in pressure or temperature) in
the vessel where the sorbent is contained. A make-up flow of fresh
sorbent can be used to compensate for natural loss of activity
and/or sorbent losses.
[0099] Amine scrubbing technology can be used to remove acid gases
from process gases. Primary amines (e.g., MEA, DGA), secondary
amines (e.g., DEA, DIPA), tertiary (e.g., MDEA, TEA), sterically
hindered amines, chilled ammonia, potassium carbonate, and other
compounds can be used to remove CO.sub.2 from process gases.
Traditional amine based systems can be characterized by high energy
requirements and solvent degradation. Improved solvents, which can
require less energy for regeneration of the solution, include the
Benfield process and two stage diethanolamine. Combination with an
OCM process can reduce the energy consumption of amine scrubbing
processes. Improved solvents can reduce the energy requirements by
as much as 40% compared to the traditional MEA solvents. This has
the potential of reducing the energy, and hence steam, consumption
of the OCM process, thereby increasing the amount of steam
available for export from the OCM, or making alternative waste heat
recovery methods feasible.
[0100] Physical absorption solvents used can include but are not
limited to glycol dimethylethers (e.g., Selexol) and propylene
carbonate (e.g., IPTS/EC). Regeneration of the solution can be
performed by vacuum flashing and air stripping; this approach can
consume significantly less energy than in chemical absorption. In
using physical solvents CO.sub.2 can be released mainly by
depressurization, thereby avoiding the high heat of consumption of
amine scrubbing processes.
[0101] Mixed or hybrid solvents can include but are not limited to
Sulfinol.TM. (sulfolane, water, and amine), such as Sulfinol-M and
Sulfinol-X.
[0102] Solid adsorbents, such as zeolites and activated carbon, can
be used to separate CO.sub.2 from gas mixtures. In pressure swing
adsorption (PSA), a gas mixture can flow through a packed bed of
adsorbent at elevated pressure until the concentration of the
desired gas approaches equilibrium. The bed can be regenerated by
reducing the pressure. In temperature swing adsorption (TSA), the
adsorbent can be regenerated by raising its temperature. In general
usage, adsorption is not yet considered attractive for large scale
separation of CO.sub.2 because the capacity and CO.sub.2
selectivity of available adsorbents are low. However, when the OCM
process is a recycle process, an adsorbent based separation method
can be used to separate bulk CO.sub.2 followed by consuming the
remaining CO.sub.2 in a methanation reactor system, or by using a
caustic scrubber to treat the remaining CO.sub.2.
[0103] Many different types of membrane materials (e.g., polymeric,
metallic, ceramic) can be used for CO.sub.2 capture to
preferentially separate CO.sub.2 from a range of process streams.
FIG. 5B shows an exemplary schematic of separation of CO.sub.2 from
a gas stream 530 in a separation vessel 520 using a membrane 521.
CO.sub.2 can be removed from the stream via the membrane, and
CO.sub.2 and other gases can exit the vessel in separate streams
531 and 532. The main limitation of currently existing membranes is
the occurrence of severe plasticization of the membrane in the
presence of high pressure CO.sub.2. Due to excessive swelling of
the polymer membrane upon exposure to CO.sub.2, the performance
(e.g., selectivity) can decrease significantly, thus reducing the
purity of the CO.sub.2 and consequently reducing the possibilities
for reuse of the gas. Energy requirements can be significantly
lower for membrane based technologies; for example, membrane
technology can use 70-75 kWh per ton of recovered CO.sub.2 compared
to significantly higher values for pressure swing adsorption (e.g.,
160-180 kWh), cryogenic distillation (e.g., 600-800 kWh), or amine
absorption (e.g., 330-340 kWh), making membrane technology an
attractive option for integration with OCM for CO.sub.2
separation.
[0104] Membrane and amine technologies can be combined to form a
hybrid process to capture CO.sub.2. Micro-porous hollow fiber
membranes can be used for CO.sub.2 separation using amine-based
chemical absorption processes. Micro-porous membranes can be used
in a gas-liquid unit where the amine solution is contacted with
CO.sub.2 containing gas. Using the membrane can lead to a reduction
in the physical size and weight of the gas-liquid contacting unit.
The separation is based on reversible chemical reaction, and mass
transfer occurs by diffusion of the gas through the gas/liquid
interface as in traditional contacting columns. Such a hybrid
membrane contactor can provide a high contact area between gas and
liquid, reduce or essentially eliminate foaming and flooding
problems, and give better operational flexibility while reducing
solvent degradation problems.
[0105] A membrane contactor can combine the advantages of membrane
technology and solvent absorption for CO.sub.2 separation. A
membrane contactor is a combination of advanced membrane techniques
with an effective absorption process. A membrane contactor is a
hybrid mass exchanger where a porous membrane separates two phases.
The selective sorbent performs the separation while the membrane
facilitates the mass exchange process by expanding the phase
contact surface area. The modified surface properties can improve
the selectivity of the process by selectively inhibiting the
transport of one of the mixture constituents. Compared to a
conventional column device, membranes can allow for up to five
times increase in yield per unit volume. Since the sorptive liquid
flows within capillaries and both phases are not directly
contacting each other, membrane absorbers can operate in any
spatial configuration (horizontal or vertical) and at any flux
rations between both phases. Also, there is no flooding or uneven
packing moisturization. Since the system operates with unchanging
yields, independent of the diameter and height; scaling up is
fairly simple. Membranes used can be micromembranes or
ultrafiltration membranes made a variety of different polymer and
ceramic materials. Polypropylene fiber membranes can be used to
separate CO.sub.2 from CH.sub.4, for example by using amines like
MEA as absorption liquid. Hollow fiber membranes, such as porous
polypropylene, perfluoroalkoxy (PFS), and asymmetric poly(phenylene
oxide) hollow fiber membranes with a dense ultrathin skin at the
outside of the membrane can also be used. Besides amines as
absorption liquid, other absorption liquids may be used, such as
aqueous sarcosine salt solutions, for example in a gas-liquid
membrane contactor system. A membrane contactor can be used to
separate the CO.sub.2 from the OCM effluent in which CH.sub.4 is
the major component. Membrane contactors can also be used for
separation of olefins and paraffins, and the separation of CO.sub.2
from light gases.
[0106] An activator, such as piperazine, diethanolamine, and
arsenic trioxide, can be used to further enhance the effectiveness
of CO.sub.2 capture. DGA and tertiary amines may provide more
improvement than primary or secondary amines.
[0107] Gas selective poly ionic liquid membranes, which are
polymerized room temperature ionic liquids (RTIL), can be used to
be highly selectively separate CO.sub.2. RTILs can be synthesized
as a monomer and subsequently polymerized to obtain gas selective
membranes. The ionic nature of the polymers can result in tight
arrangements between the oppositely charged ionic domains in the
poly RTIL, which can eventually prevent the membrane from excessive
swelling and deterioration of its performance at increased pressure
and/or temperature. This intrinsic property of poly RTIL can be
used to increase the resistance against plasticization and to
restrict strong swelling of the polymer membrane to maintain its
permeation properties in the presence of a strong plasticizing
agent such as CO.sub.2 at higher pressures. For example, an
imidazolium-based poly RTIL can be used as base material and the
length of the alkyl chain can serves to strengthen or weaken the
ionic interactions within the poly RTIL. High pressure mixed
CO.sub.2/CH.sub.4 gas separation measurements at different
temperatures.
[0108] Gas components like CO.sub.2, from N.sub.2 or CH.sub.4 can
be separated with supported ionic liquid membranes. Ionic liquids
are molten salts with a very low melting point (many are liquids at
room temperature). Many ionic liquids show a high solubility for
carbon dioxide and hence can be highly suitable for use with an OCM
process. For example, ionic liquids can include but are not limited
to imidazolium, pyrollidinium, pyridinium, cuanidinium,
phosphonium, morpholinium, piperidinium, sulfonium, ammonium,
hexafluorophosphate, tetraflouroborate, alkylsulphate, triflate,
dicyanamide, bis(trifluoromethylsulfonyl)imide, and combinations
thereof. Specific advantages of ionic liquids include very low to
negligible vapor pressure, good dissolution characteristics for
many substances, and lack of flammability or toxicity. Ionic
liquids can have good thermal, mechanical and chemical stability as
well as favorable densities and viscosities. The required
specifications can be adjusted easily by the large number of
possible combinations of anions and cations when formulating an
ionic liquid. Ionic liquids can be used as chemical solvents,
catalysts, electrolytes in fuel cells as well as for gas-separation
and storage by absorption. Ionic liquid membrane systems can
comprise an adequate porous support material, e.g. a polymer film,
coated by ionic liquids. The system separated CO.sub.2 and sulfur
compounds from different gas mixtures. Competitive selectivity and
permeability are obtained for the separations.
[0109] Novel membrane materials, such as polyetherimides, can be
used as membrane material with improved plasticization resistance
for CO.sub.2 removal, for example with an OCM process. Other
membrane materials that can be used include polymeric membranes
based on polyamides, polysemicarbazides, polycarbonates,
polyarylates, polyaniline, poly(phenylen oxide), polysulfones, and
polypyrrolones. In some cases, the polymeric membrane is solvent
resistant and can reduce the plasticization effects of hydrocarbons
in the feed stream, e.g., polyketone, polyether ketone, polyarylene
ether ketone, polyimide, polyetherimide, and polyphenylene
sulphide, which have intrinsic solvent inertness and can therefore
withstand organic rich operation conditions.
[0110] An adequate porous support material, e.g. a polymer film,
coated by ionic liquids can be used in continuous separation of
CO.sub.2 and sulfur compounds from different gas mixtures,
including a methane rich stream. This separation can improve the
efficiency of OCM processes. The OCM reactor effluent can enter the
supported ionic liquid separation subsystem, and CO.sub.2 and other
contaminants can be removed from the process gas. Other
contaminants can include but are not limited to traces of sulfur
compounds, inerts, CO, SO.sub.2, H.sub.2S, and tetrahydrothiophene
(THT).
[0111] CO.sub.2 can be separated from other gases by cooling and
condensation, for example as shown in FIG. 5C. A stream containing
CO.sub.2 550 can be compressed in a compressor 540, and the
compressed stream 551 can be directed to a distillation column 541.
Some components can be recovered from the overhead stream 552, with
heat recovered in a heat exchanger 542. Other components can be
recovered from the bottoms 555. Cryogenic separation is widely used
commercially for streams that already have a high concentration of
CO.sub.2 (typically greater than 90%). Cryogenic separation of
CO.sub.2 has the advantage that it enables direct production of
high purity liquid CO.sub.2 that can be used as a feedstock to
convert the carbon to higher value hydrocarbons, or otherwise be
captured. The amount of energy required can be high, and water may
need to be removed before the feed gas is cooled.
[0112] Low temperature distillation can give better results when
there is a high concentration of CO.sub.2 in the feed gas. For the
OCM process gas, the CO.sub.2 concentration can be increased by,
for example, having a recycle stream, or by using a modified OCM
reactor where excess CO.sub.2 is used as a quench medium for the
reaction heat. Low temperature separation can refer to separations
using temperature levels above -90.degree. C.
[0113] FIG. 6 shows a schematic of CO.sub.2 separation using
distillation. OCM reactor effluent 606 can be fed to a treatment
unit 601, such as a molecular sieve dryer, a sulfur removal bed, or
an acetylene removal bed. The treated gas is fed to the first
distillation column 602 that separates the bulk of the methane from
the CO.sub.2 and other heavier hydrocarbons. Depending on the
CO.sub.2 concentration in the stream 606, the bottom stream 608 may
contain 50%, 60%, 70%, 80%, 90% (or anywhere in between) of the
incoming CO.sub.2. The overhead from 607 contains majority of the
methane and other light gases and is fed to the column 603. Column
603 further recovers methane rich gas 611, which can be the feed to
a methanation system. The bottoms product 616 may be recycled or
sent as a purge to the fuel gas system. The CO.sub.2 rich gas 608
is distilled in the CO.sub.2 column 604 to recover pure CO.sub.2
609 in the overhead. The bottoms product 610 can contain some
methane along with ethane, ethylene, and other heavier
hydrocarbons, and can be sent to recover the ethylene product in a
separator 605. The CO.sub.2 product can be sent to methanation
unit, and a part of the CO.sub.2 can be recycled to achieve the
desired concentration of CO.sub.2 in the feed stream 606. Such a
CO.sub.2 distillation sub system can offer many benefits, including
but not limited to reducing the loop size of the OCM process
considerably, as the function of the existing cryogenic
demethanizer can be reduced by a large extent. Additionally, amine
and caustic systems can be replaced by cryogenic or low temperature
distillation systems.
[0114] Alkaline salt-based processes can be used for carbon dioxide
removal. These processes can utilize the alkali salts of various
weak acids, such as sodium carbonate and potassium carbonate. These
processes can provide advantages such as low cost and minimal
solvent degradation. Processes that can be used for H.sub.2S and
CO.sub.2 absorption include those using aqueous solutions of sodium
or potassium compounds. For example, potassium carbonate can absorb
CO.sub.2 at high temperatures, an advantage over amine-based
solvents.
[0115] Hot potassium carbonate (K.sub.2CO.sub.3) solutions can be
used for the removal of CO.sub.2 from high-pressure gas streams,
among other applications. Potassium carbonate has a low rate of
reaction. To improve CO.sub.2 absorption, mass transfer promoters
such as piperazine, diethanolamine, and arsenic trioxide can be
used. Less toxic promoters such as borate can also be used, for
example with flue gas streams (see, e.g., Ghosh et al., "Absorption
of carbon dioxide into aqueous potassium carbonate promoted by
boric acid", Energy Procedia, pages 1075-1081, February 2009, which
is hereby incorporated by reference in its entirety). To limit
corrosion, inhibitors can be added. These systems can be known as
activated hot potassium carbonate systems. Licensed hot activated
potassium carbonate systems include the Benfield.TM. and the
Catacarb.TM. process. The processes can be used for bulk CO.sub.2
removal from high-pressure streams, but can also produce
high-purity CO.sub.2.
[0116] Flue gas impurities such as SOx and NOx can reduce the
operational efficiency of the potassium carbonate as a solvent.
SO.sub.2 and NO.sub.2 may not able to be released from the solvent
under industrial conditions. Selective precipitation of the
impurity salts formed by SOx and NOx can be used to remove such
compounds (see, e.g., Smith et al., "Recent developments in solvent
absorption technologies at the CO2CRC in Australia" Energy
Procedia, pages 1549-1555, February 2009, which is hereby
incorporated by reference in its entirety).
[0117] A variety of materials can be used as CO.sub.2 sorbents
through chemical reactions and physical absorptions, including but
not limited to soda-lime, active carbon, zeolites, molecular
sieves, alkali metal oxides, silver oxide, lithium oxide, lithium
silicate, carbonates, silica gel, alumina, amine solid sorbents,
metal organic frameworks and others.
[0118] Physical impregnation of CO.sub.2-reactive polymers, such as
tetraethylene pentamine or polyethyleneimine, inside a porous
support, such as alumina, pumice, clay or activated carbon, can be
used for CO.sub.2 removal. Amine based sorbents can be easily
regenerated. Alternatively, a mixture of an amine compound with a
polyol compound can be impregnated in a porous support. The polyol
compound can be used to increase the CO.sub.2 desorption rate of
the amine. The supported amine-polyol sorbent can comprise from
about 1 wt % to about 25 wt % amine and from about 1 wt % to about
25 wt % polyol, with the balance being the support. Solid sorbent
can adsorb and desorb CO.sub.2 a relatively high rates at ambient
temperatures Enhanced CO.sub.2 cyclic removal capacities in either
dry or humid air flows can further be achieved by using a solid
sorbent at an increased amine concentration of amines from about 35
wt % to about 75 wt %.
[0119] Solid sorbents that can selectively remove multiple gases
can be used to remove CO.sub.2, H.sub.2O, nitrogen oxides, and
hydrocarbons. This can be achieved by using composite adsorbents,
for example by using a mixed adsorbent of alumina and zeolite to
remove CO.sub.2 and H.sub.2O simultaneously.
[0120] CO.sub.2 can be separated from flue gas using an ion pump
method instead of relying on large temperature and pressure changes
to remove CO.sub.2 from a solvent. Ion pump methods can
dramatically increase the overlying vapor pressure of CO.sub.2. As
a result, the CO.sub.2 can be removed from the downstream side of
the ion pump as a pure gas. The ion pumping can be obtained from
techniques including but not limited to reverse osmosis, electro
dialysis, thermal desalination methods, or an ion pump system
having an oscillation flow in synchronization with an induced
electric field.
[0121] By making use of energy such as renewable or nuclear energy,
carbon dioxide and water can be recycled into sustainable
hydrocarbon fuels in a non-biological process. Various pathways can
enable such a conversion, for example by H.sub.2O and CO.sub.2
dissociation followed by fuel synthesis. The methods of
dissociation can include heat, electricity, and solar driven
methods such as thermolysis, thermochemical loops, electrolysis,
and photoelectrolysis. High temperature electrolysis can make
efficient use of electricity and heat, provide high reaction rates,
and integrate well with fuel synthesis.
[0122] Synthetic analogues of enzymes as a polymer thin film
supported on micro-porous substrates can be used to separate
CO.sub.2 from gas mixtures. For example, a polymer thin film
containing carbonic anhydrase mimicking sites can supported on a
porous substrate and can separate CO.sub.2 from a stream containing
O.sub.2 and N.sub.2. The system can be, for example, about 30%
lower in cost compared to amine-based systems.
Process Configurations
Electrolysis to Generate Oxygen and Hydrogen for OCM Process
[0123] Electrolysis can be used to produce industrial hydrogen. OCM
processes can have a lot of synergistic benefit from deploying a
water electrolysis subsystem with the OCM process. The water
electrolysis unit can replace an air separation unit (ASU) to
supply the oxygen required for the OCM process. The products from
the electrolytic unit can be consumed within the OCM process:
oxygen can be consumed within the OCM reactor and hydrogen can be
used in a methanation reactor. Availability of more hydrogen in the
methanation unit has the potential to increase the carbon
efficiency to about 100%, by converting the CO.sub.2 produced in
the OCM reaction to methane, which can be recycled back to the OCM
reactor. The OCM unit can be a net exporter of high purity excess
hydrogen, after consuming the entirety of the CO.sub.2 produced in
the OCM Process.
[0124] The water electrolysis subsystem can be an electrolytic cell
employing alkaline water electrolysis, a proton exchange membrane
electrolysis system, or a steam electrolysis system. The
electricity source to the electrolytic sub system can be renewable,
such as photo voltaic/solar power, which can make the entire system
100% carbon efficient with a zero carbon footprint. A storage
system for oxygen, or a backup power supply, may be used to ensure
the continuous supply of oxygen and hydrogen.
[0125] With steam electrolysis, a substantial part of the energy
needed for the electrolysis process can be added as heat, which can
be much cheaper than electric energy, and which the OCM reactor can
produce in abundance. Therefore, integration of steam electrolysis
can take advantage of the extra heat from the OCM reactor to
provide energy for the steam electrolysis. This can be of
particular benefit to OCM deployments where no additional steam or
power is required.
[0126] FIG. 7 depicts an exemplary electrolysis subsystem combined
with an OCM system. The electrolysis subsystem 701 can take water
710 and electric power 711 as inputs and generate pure oxygen 712
and hydrogen 713 as products. The oxygen can be fed into an OCM
reactor 702 with a methane feed 714, for conversion to higher
hydrocarbon products including ethylene. The OCM product stream can
be compressed in a compressor 704 and separated in a separations
unit 705. Higher hydrocarbon products 716 can be recovered from the
separations unit, and other compounds such as methane and CO.sub.2
can be recycled 717 and/or purged 718. The recycle stream can be
directed to a methanation unit 703, which can generate methane 715
using the hydrogen from the electrolysis subsystem. The extra
hydrogen that is now available to the methanation unit can enable
the conversion of most or all of the CO.sub.2 produced in the OCM
process to methane, which can drive the process to a higher
efficiency. The process can also be almost 100% emission free. The
CO.sub.2 produced in the process that may be discarded as waste may
be converted to methane and hence to ethylene in the OCM
reactor.
Different Quench Media for the OCM Reaction
[0127] The OCM reaction is highly exothermic. Various quenching
media can be used to extract the OCM reaction heat. For example,
CO.sub.2 can be injected to extract the heat, which results in the
OCM effluent containing excess CO.sub.2; such effluent can be
suitable for the advanced CO.sub.2 recovery methods described
herein. FIG. 8 shows an exemplary system where CO.sub.2 814 is
removed from an OCM product stream 812 (generated in an OCM unit
801 from an oxygen stream 810 and a methane stream 811) in a
CO.sub.2 separation unit 802 and recycled from back to the OCM
reactor 801. A waste gas or purge stream 815 can also be removed
from the CO.sub.2 separation unit. The OCM product stream 813 can
then be separated in a separations unit 803 into a product stream
816 comprising ethylene and a purge and/or recycle stream 817.
Separation methods can include low temperature separation, membrane
separation, or other separation methods discussed herein. The OCM
loop can be decreased to just a CO.sub.2 recycle stream. The system
can also comprise a methanation unit (not shown).
[0128] Such an approach can provide advantages including a smaller
recycle loop and more efficient CO.sub.2 removal methods, resulting
in lower capital expenditure (CAPEX). This can also result in the
feasibility of small distributed scale OCM units, since after the
removal of excess CO.sub.2, the relatively richer ethylene stream
needs fewer treatment and recovery steps.
Heat Recovery
[0129] Waste heat from the OCM process can be used to generate
superheated high pressure steam that can be used in the process,
exported to other users on site, or can be used to generate power.
Excess process heat can also be used to preheat the feed streams.
Other uses for excess heat can be less capital intensive, and offer
a greater operational flexibility and low maintenance.
Thermoelectric energy conversion can be used to convert waste heat
to power. Example uses for waste heat include single fluid rankine
cycles (e.g., steam cycle, hydrocarbons, and ammonia), binary/mixed
fluid cycles (e.g., ammonia/water or mixed hydrocarbon cycle).
Organic Rankine Cycle
[0130] The organic Rankine cycle (ORC) can be used to generate
power from heat. In ORC, an organic component is used instead of
water. The organic compound can be a refrigerant, a hydrocarbon
(e.g., butane, pentane, hexane), silicon oil, or a perfluorocarbon.
The boiling point of the organic fluid can be lower than that of
water, which can allow recovering heat at a lower temperature than
in the traditional steam Rankine cycle.
[0131] Owing to the exothermicity of the OCM reaction, the ORC
system can be deployed as a waste heat recovery method for use with
OCM. Waste heat at relatively low temperature can be recovered by
an intermediate heat transfer loop and used to evaporate the
working fluid of the ORC.
[0132] FIG. 9 shows an exemplary OCM system with an ORC subsystem.
The working fluid can be chosen which can be condensed with cooling
water or air at normal atmospheric pressure. FIG. 9 shows the heat
source as the OCM reaction heat from an OCM unit 901. Heat can be
recovered from the OCM product stream 910 in an evaporator 902, and
the product stream 911 can then be directed for downstream
processing from the OCM unit. The heat recovered in the evaporator
can be used to evaporate a working fluid stream 912, which can then
be directed to a turbine 903 to generate power in a generator 904.
From the turbine, the working fluid 913 can be directed to a
condenser 905 and cooled using a cooling medium 914. The cooled
working fluid 915 can then be pumped by a pump 906 in a stream 916
back to the evaporator.
Thermoelectric Power Generation
[0133] The OCM process can make use of a heat exchanger with
thermoelectric (TE) generators for heat recovery. A Thermoelectric
Power Generator (TPG) can have four basic components: Heat source,
P and N type semiconductor stack (or a TE module), heat sink (cold
side), and an electrical load (output voltage). The TE module can
include two or more of P-type and N-type semiconductor pellets
connected in series or parallel depending on the served load.
[0134] The TE devices can be solid state engines that do not
require any working fluid. Thermoelectric materials can provide
efficiencies of up to 15% or greater. Thermoelectric generators
coupled with heat exchangers can produce electricity even at
temperatures as low as 350 K with low maintenance. TE modules can
be used with OCM including large bulk TE modules and thin film or
micro TE modules.
[0135] For high temperatures, micro TE modules can be used. Micro
TE modules can also have low equipment weights. TE devices can be
very reliable, scalable, and modular. Some TE modules can give best
results at small scales. The OCM process can generate medium level
waste heat that is highly suitable for a TE device to generate
power.
OCM and ETL Systems with Advanced Separations Sub-Systems
[0136] PSA technology can be applied to processes including those
involving a hydrocarbon stream containing a mix of the following
hydrogen, carbon dioxide, carbon monoxide, methane, ethane,
ethylene, propane, propylene, butanes, butenes and/or other higher
hydrocarbons needing to be purified or separated into desirable
products (e.g., ethylene, methane, hydrogen, or propylene).
[0137] Hydrocarbon streams can be produced via traditional refining
and petrochemical processes. Hydrocarbon streams can be produced
from OCM or ETL reactor systems.
[0138] The present disclosure provides the use of PSA in processes
and systems for oxidative coupling of methane (OCM) and
ethylene-to-liquids (ETL) operations, and the application of
adsorbent based processes used in conjunction with OCM and ETL
processes to generate significant process improvements and enhance
the economic value of the processes. OCM systems are described in,
for example, U.S. patent application Ser. No. 14/592,668, which is
entirely incorporated herein by reference. ETL systems are
described in, for example, U.S. patent application Ser. No.
14/591,850, which is entirely incorporated herein by reference.
[0139] An OCM system, such as that shown in FIG. 10, can include an
OCM or OCM-post-bed-cracking (PBC) reactor 1002, a process gas
compression system 1003, a process gas treatment system 1004, a
cryogenic separations system, and a methanation system 1001. The
feed to the OCM system can be an oxygen feed 1012 and a methane
source feed 1011 (such as a natural gas feed stream or other
methane source). In some cases, additional ethane feed can be
supplied to the PBC section of the OCM reactor, where paraffins
such as ethane in the OCM product stream and/or additional ethane
can be cracked to olefins such as ethylene. The separations
sub-system can comprise a series of fractionation towers, like a
demethanizer 1005, deethanizer 1006, C.sub.2 splitter 1007,
depropanizer 1008, debutanizer, and others. Overhead 1013 from the
demethanizer can be directed into the methanation system along with
hydrogen or natural gas 1010 to produce additional methane. The
bottoms stream 1014 from the demethanizer can be directed to the
deethanizer. The overhead stream 1015 from the deethanizer can be
directed to the C.sub.2 splitter, and there split into ethylene
1016 and ethane 1017 streams. The bottoms stream 1018 from the
deethanizer can be directed to the depropanizer, and there split
into a C.sub.3 product stream 1019 and a C.sub.4+ product stream
1020. The cryogenic separations system can comprise additional
ethylene and propylene refrigeration sub-systems to provide for the
chilling requirements of the system.
OCM process standalone with advanced separations systems
[0140] In certain cases, the separations section of the OCM system
can be eliminated, or partially eliminated, by utilizing an
advanced separations method as discussed in this application. The
advanced separation method can be a PSA unit or a membrane based
method, or a cryogenic system. FIG. 11 shows an exemplary schematic
of OCM with a PSA unit. The PSA unit can separate methane,
CO.sub.2, CO, and/or H.sub.2 from ethane, ethylene, propane,
propylene, and/or higher hydrocarbons. Methane 1111 and oxygen 1112
can be directed into an OCM reactor 1102 and reacted to produce
higher hydrocarbon products including ethylene. The OCM product can
be compressed in a process gas compression system 1103, treated in
a process gas treatment system 1104, and separated in the PSA 1105
into a product stream 1113 and a recycle stream 1114. The recycle
stream can be directed to a methanation unit 1101, which can also
receive a natural gas stream 1110 and produce methane for the OCM
reactor. The extent of separation and degree of recovery can depend
on the type of adsorbent(s), pressure differential, and number of
PSA stages employed. The feed to the PSA unit can have one or more
of the following components: H.sub.2, N.sub.2, O.sub.2, CO,
CO.sub.2, CH.sub.4, ethane, ethylene, acetylene, propane,
propylene, butanes, butenes, butadiene, water, and higher
paraffinic and olefinic components. The PSA product gas can
comprise components including but not limited to: H.sub.2, N.sub.2,
CO, CO.sub.2, CH.sub.4, O.sub.2, ethane, ethylene and acetylene.
PSA product gas can comprise components from 0% to 99.99% recovery.
The PSA tail gas can comprise 99.99%, 90%, 80%, 70%, 60%, 50%
ethylene. The PSA tail gas can comprise at least 99.99%, 90%, 80%,
70%, 60%, 50% ethylene. The PSA tail gas can comprise about 99%,
90%, 80%, 70%, 60%, 50%, 40%, 30%, 20%, 10%, 0% ethane. The PSA
tail gas can comprise at least about 99%, 90%, 80%, 70%, 60%, 50%,
40%, 30%, 20%, 10%, 0% ethane. The PSA tail gas can comprise about
60%, 50%, 40%, 30%, 20%, 10%, 0% methane, hydrogen, acetylene,
N.sub.2, O.sub.2, H.sub.2O or CO.sub.2. The PSA tail gas can
comprise at least about 60%, 50%, 40%, 30%, 20%, 10%, 0% methane,
hydrogen, acetylene, N.sub.2, O.sub.2, H.sub.2O or CO.sub.2. Based
on the process configuration, including the type of adsorbents
employed, pressure differential and the operation, various
different recoveries are possible.
[0141] As discussed above, the PSA unit can comprise one or more
adsorbent materials that can be suitable to achieve the component
recoveries. The sorbent can be a zeolite/molecular sieve based
material, a carbon based sorbent, or a .pi.-complexation sorbent.
In some cases the sorbent material can be a polymeric resin, carbon
nanotubes, and carbon fibers. The PSA unit can be configured to
have layers of different sorbents so as to result in high
recoveries from the multi-component feed streams to the desired
products.
[0142] In certain cases the PSA can be a multi stage unit (see,
e.g., FIG. 12). In such a unit, an OCM reactor 1202 can receive a
methane stream 1211 and an oxygen stream 1212, and react the
methane and oxygen to produce higher hydrocarbon products including
ethylene in an OCM product stream. The OCM product stream can be
compressed in a first compressor 1203 and directed to a first PSA
separation 1204. The tail gas 1214 from the first PSA can be
compressed in a second compressor 1205 and fed to a second PSA
separation 1206, the tail gas 1216 from which can be compressed in
a third compressor 1207 and separated in a third PSA separation
1208. The tail gas from the third PSA can be the final purified
stream 1217 containing ethylene up to 99.9% purity. PSA product
streams 1213, 1215, and 1218 can be directed to recycle, such as
via a methanation unit 1201 along with a natural gas stream 1210.
Each PSA stage can be a dual-bed PSA or a multi-bed PSA system.
[0143] In certain cases, the process requirements can dictate that
only a limited amount of recovery is required in the PSA unit and
subsequent recovery and purification is performed in a
fractionation column or the gas is a feed for a downstream process
unit. The downstream process unit can be an ETL system, an ethylene
steam cracker system, a gas processing plant, NGL extraction plant,
a refinery off-gas separations system, or other process unit.
Retrofits for OCM
[0144] OCM can be employed to convert a feedstock comprising
methane to ethylene and other olefins. Historically, ethylene has
been produced via steam cracking of gaseous or liquid hydrocarbon
feedstocks like ethane, propane, LPG, or naphtha. As in most of the
refining and petrochemical operations, a steam cracking operation
can involve a cryogenic fractionation or a separations section that
consists of a series of fractionation columns to successively
recover various components at high product purity.
[0145] The present disclosure includes the application of PSA
processes to an OCM retrofit of an existing ethylene cracker (e.g.,
steam cracker).
[0146] An example application for OCM combined with a PSA unit
involves an existing petrochemical plant such as a steam cracker is
considering low cost ways to add ethylene capacity. A typical
revamp to add capacity could include addition of, or
debottlenecking of, the existing fractionation towers for the
entire flow addition for the revamp. However, as shown in FIG. 13,
the use of a PSA unit as disclosed herein can provide a low cost
alternative to traditional revamps. An OCM unit with a PSA unit
retrofitted to an existing steam cracker can be an effective way of
adding ethylene capacity at a low marginal cost. The advantages of
adding a PSA unit include that no additional cryogenic separation
is required for the added capacity. For ethylene revamps, one of
the key areas during debottlenecking may be the refrigeration
systems and/or the fractionation columns, but utilizing the PSA to
separate or pre-separate the additional product stream can result
in a simpler and easier debottlenecking. As in shown in FIG. 13,
for example, the tail gas from the PSA can be sent to the cracker
system where the ethylene is recovered.
[0147] FIG. 13 shows an example of an OCM process integrated with
an existing ethylene cracker using a PSA system for separations.
The OCM reactor 1301 takes in methane 1310 and oxygen 1311 and
produces an OCM effluent 1312 having CO.sub.2, CH.sub.4 and
C.sub.2H.sub.4, in some cases amongst other components, such as
H.sub.2 and CO. The OCM reaction can be exothermic and can produce
steam 1313. The OCM effluent can be compressed in a compressor 1302
and optionally treated in an acid gas removal system 1303, and fed
into a pressure swing adsorption (PSA) unit 1304. In some cases the
acid gas removal system may have an additional knock out drum to
condense and separate any condensates and water. It also can
include a drier to remove water. The PSA unit can produce a product
stream that can include H.sub.2, CH.sub.4, ethane, CO.sub.2 and CO.
The overhead stream 1315 can be fed into a methanation subsystem
1305 (e.g., methanation reactor) to provide methane for the OCM
reactor, and some of the overhead stream can be purged 1316 to a
fuel gas system, for example. Additional methane can be provided by
way of a natural gas stream or other methane stream. The PSA tail
gas 1317 can comprise most of the ethylene, the content of which
may range from 50% to 99.9% depending on the process configuration
and operation of the PSA system. The PSA tail gas can also comprise
H.sub.2, CO, CO.sub.2, CH.sub.4, ethane, propane, propylene,
butanes, butenes, and other components. The process of FIG. 13 can
further include an existing ethylene cracker 1306. The PSA tail gas
can be fractionated using existing separations capacity in the
ethylene cracker. The heavy components can be processed in the
fractionation towers of the ethylene cracker, optionally first
being compressed in the existing process gas compressor of the
ethylene cracker. In some cases, the heavy components stream can be
routed to the CO.sub.2 removal unit of the existing ethylene
cracker subsystem to meet the CO.sub.2 specification. The OCM
reactor can receive a C.sub.2 recycle stream 1319 from the cracker
complex.
[0148] The combination of a new OCM unit and an existing ethylene
cracker can provide synergistic benefits. It can provide for a low
cost alternative to add ethylene capacity to the existing cracker.
In some cases, prior to retrofit of an ethylene cracker with OCM,
the entire overhead from the existing demethanizer is used as fuel
gas, and can now be available as one of the feeds to the
methanation unit. In some cases, the demethanizer overhead off-gas
comprises up to 95% methane, which can be converted to ethylene in
the OCM reactor, hence increasing the total ethylene capacity. In
some cases, the hydrogen content in the existing demethanizer
overhead is substantial, and may be enough to meet the hydrogen
requirement of the methanation unit.
[0149] In some cases, retrofitting an ethylene cracker with OCM
reduces (or allows for reduction of) the severity of cracking in
the existing cracker, enabling value addition by increasing the
production of pyrolysis gasoline components in the cracker
effluent, as the OCM reactor produces the ethylene that may be
needed to achieve the total system capacity. The cracker can then
be operated on high propylene mode to produce more propylene and at
the same time meeting the ethylene production rate by the new OCM
unit. This retrofit can result in greater flexibility for the
ethylene producer with respect to the existing cracker
operation.
[0150] In some instances, the overall carbon efficiency can be
increased as the methane and hydrogen from the existing
demethanizer off-gases can be utilized to convert the carbon
dioxide and carbon monoxide to methane, which is fed to the OCM
reactor.
[0151] In some instances, ethane and/or propane recycle streams
from the existing cracker can be routed to the OCM unit (e.g.,
instead of the cracking furnaces). These recycle streams are
typically routed to the cracking furnaces where they are cracked to
extinction. This can provide an advantage over routing the recycle
streams to OCM over the cracking furnace, such as higher
selectivity to ethylene in the OCM process.
[0152] In certain cases, more than one stages or PSA columns may be
employed to achieve higher recovery and higher product purity. As
in shown FIG. 14, for example, up to 99.9% recovery is possible
using the multi stage PSA units. An OCM reactor 1402 can receive a
methane stream 1410 and an oxygen stream 1411, and react the
methane and oxygen to produce higher hydrocarbon products including
ethylene in an OCM product stream. The OCM product stream can be
compressed in a first compressor 1403 and directed to a first PSA
separation 1404. The tail gas 1412 from the first PSA can be
compressed in a second compressor 1405 and fed to a second PSA
separation 1406, the tail gas 1414 from which can be compressed in
a third compressor 1407 and separated in a third PSA separation
1408. The tail gas from the third PSA can be the final purified
stream 1417 can be directed to a cracker unit, such as an existing
cracker unit, where it can be processed and separated into an
ethylene product stream 1418, a propylene product stream 1419, and
an additional product stream 1420. PSA product streams 1413, 1415,
and 1416 can be directed to recycle, such as via a methanation unit
1401, along with a demethanizer off gas stream 1421 from the
cracker unit. Each PSA stage can be a dual-bed PSA or a multi-bed
PSA system.
[0153] The application of a PSA unit to OCM systems, standalone or
retrofits to existing facilities exhibits immense potential in
terms of cost savings and ease of integration and retrofit to
existing facilities.
ETL Systems
[0154] FIG. 15 shows various exemplary configurations for an
OCM-ETL process. In the upper left, FIG. 15 shows a stand alone
skimmer configuration, where a methane stream 1505 can be directed
into an OCM reactor 1501 with an oxygen feed 1506 and optionally an
ethane feed 1507. The OCM reactor product stream can be directed
into a compressor 1502 and then into an ETL reactor 1503. The ETL
product stream can be directed into a gas separations unit 1504,
where it can be separated into a C.sub.2+ product stream 1508, a
C.sub.5+ product stream 1509, and an overhead stream 1510
comprising methane which can be returned to a pipeline, sold to a
consumer, or otherwise used. In the upper right, FIG. 15 shows a
stand alone recycle configuration, where a methane feed stream 1518
(e.g., from a natural gas pipeline) is directed into a treatment
unit 1511 and then into a separations system (e.g., cryogenic)
1512. A methane feed stream 1519 can be directed to an OCM reactor
1513, while another methane stream 1520 can be purged or used for
power generation. A C.sub.2+ stream 1521 can also be recovered from
the separations system. An oxygen feed stream 1522 and optionally
an ethane stream 1523 can also be directed into the OCM reactor,
and the reactor can produce an OCM product stream. The OCM product
stream can be directed into a compressor 1514 and then into an ETL
reactor 1515. The ETL product stream can be processed in a knockout
drum 1516 or other separator to remove a C.sub.5+ product stream
1524. The remaining ETL product stream can be directed to a
compressor 1517 and recycled to the treatment unit. In the lower
left, FIG. 15 shows a hosted skimmer configuration, where a methane
stream 1532 can be directed from a separations system 1526 (e.g.,
cryogenic) into an OCM reactor 1527 with an oxygen feed 1533 and
optionally an ethane feed 1534. The OCM reactor product stream can
be directed into a compressor 1528 and then into an ETL reactor
1529. The ETL product stream can be directed into a gas separations
unit 1530, where it can be separated into a C.sub.2+ product stream
1535, a C.sub.5+ product stream 1536, and an overhead stream 1537
comprising methane which can be returned to a recompressor 1531. In
the lower right, FIG. 15 shows a hosted recycle configuration,
where a methane stream is directed into a treatment unit 1538 and
then into a separations system (e.g., cryogenic) 1539. A methane
feed stream 1546 can be directed to an OCM reactor 1541, while
another methane stream can be directed to a recompressor 1540. A
C.sub.2+ stream 1551 can also be recovered from the separations
system. An oxygen feed stream 1547 and optionally an ethane stream
1548 can also be directed into the OCM reactor, and the reactor can
produce an OCM product stream. The OCM product stream can be
directed into a compressor 1542 and then into an ETL reactor 1543.
The ETL product stream can be processed in a knockout drum 1544 or
other separator to remove a C.sub.5+ product stream 1549. The
remaining ETL product stream can be directed to a compressor 1545
and recycled 1550 to the treatment unit.
[0155] FIG. 16 shows similar configurations as FIG. 15, with an
added pressure swing adsoprtion (PSA) unit to pre-separate the OCM
effluent to remove most of the methane, hydrogen, CO and CO.sub.2
from the olefinic stream, which is then fed to the ETL reactor.
This can result in a feed to the ETL reactor that is concentrated
in olefins. Though the process remains similar, the entire ETL and
separations train becomes considerably smaller; that is, larger
capacities can be achieved in the same set-up or same footprint. In
some cases this can improve the ETL reaction operation. In the
upper left, FIG. 16 shows a stand alone skimmer configuration,
where a methane stream 1606 can be directed into an OCM reactor
1601 with an oxygen feed 1607 and optionally an ethane feed 1608.
The OCM reactor product stream can be directed into a compressor
1602 and then into a PSA unit 1603. A light stream 1609 comprising
methane, hydrogen, CO and CO.sub.2 can be directed from the PSA
back to a pipeline, sold to a consumer, or otherwise used. An
olefinic stream can be directed from the PSA to an ETL reactor
1604. The ETL product stream can be directed into a gas separations
unit 1605, where it can be separated into a C.sub.2+ product stream
1610, a C.sub.5+ product stream 1611, and an overhead stream 1612
comprising methane which can be returned to a pipeline, sold to a
consumer, or otherwise used. In the upper right, FIG. 16 shows a
stand alone recycle configuration, where a methane feed stream 1628
(e.g., from a natural gas pipeline) is directed into a treatment
unit 1620 and then into a separations system (e.g., cryogenic)
1621. A methane feed stream 1629 can be directed to an OCM reactor
1622, while another methane stream 1630 can be purged or used for
power generation. A C.sub.2+ stream 1631 can also be recovered from
the separations system. An oxygen feed stream 1632 and optionally
an ethane stream 1633 can also be directed into the OCM reactor,
and the reactor can produce an OCM product stream. The OCM product
stream can be directed into a compressor 1623, and at least a
portion 1634 of the OCM product stream can be directed from the
compressor into a PSA unit 1624. A light stream 1635 comprising
methane, hydrogen, CO and CO.sub.2 can be directed from the PSA
back to the treatment unit. An olefinic stream 1636 can be directed
from the PSA to an ETL reactor 1625. The ETL product stream can be
processed in a knockout drum 1626 or other separator to remove a
C.sub.5+ product stream 1637. The remaining ETL product stream can
be directed to a compressor 1627 and recycled to the treatment
unit. In the lower left, FIG. 16 shows a hosted skimmer
configuration, where a methane stream 1647 can be directed from a
separations system 1640 (e.g., cryogenic) into an OCM reactor 1641
with an oxygen feed 1648 and optionally an ethane feed 1649. The
OCM reactor product stream can be directed into a compressor 1642
and then into and then into a PSA unit 1643. A light stream 1650
comprising methane, hydrogen, CO and CO.sub.2 can be directed from
the PSA to a recompressor 1646. An olefinic stream can be directed
from the PSA to an ETL reactor 1644. The ETL product stream can be
directed into a gas separations unit 1645, where it can be
separated into a C.sub.2+ product stream 1651, a C.sub.5+ product
stream 1652, and an overhead stream 1653 comprising methane which
can be returned to the recompressor. In the lower right, FIG. 16
shows a hosted recycle configuration, where a methane stream is
directed into a treatment unit 1660 and then into a separations
system (e.g., cryogenic) 1661. A methane feed stream 1669 can be
directed to an OCM reactor 1663, while another methane stream can
be directed to a recompressor 1662. A C.sub.2+ stream 1677 can also
be recovered from the separations system. An oxygen feed stream
1670 and optionally an ethane stream 1671 can also be directed into
the OCM reactor, and the reactor can produce an OCM product stream.
The OCM product stream can be directed into a compressor 1664 and
at least a portion 1672 of the OCM product stream can be directed
from the compressor into a PSA unit 1665. A light stream 1673
comprising methane, hydrogen, CO and CO.sub.2 can be directed from
the PSA back to the treatment unit. An olefinic stream 1674 can be
directed from the PSA to an ETL reactor 1666. The ETL product
stream can be processed in a knockout drum 1667 or other separator
to remove a C.sub.5+ product stream 1675. The remaining ETL product
stream can be directed to a compressor 1668 and recycled 1676 to
the treatment unit.
[0156] The ETL reactor can be a tubular, packed bed, moving bed,
fluidized bed, or other reactor type. An ETL reactor can be an
isothermal or adiabatic reactor. The ETL system can benefit from a
feed concentrated in olefins. The ETL reactor system can use a
recycle stream to control and moderate the temperature increase in
the reactor bed due to the highly exothermic nature of the ETL
reactions. ETL systems are described in, for example, U.S. patent
application Ser. No. 14/591,850, which is entirely incorporated
herein by reference.
[0157] In certain embodiments, one or more of the fractionation
towers can be deemed redundant if using the PSA, as an example, a
demethanizer may not be required and the sales gas or purge gas to
fuel can be sent from the PSA itself.
Retrofit Applications for Midstream and Refining
[0158] Systems, such as those of FIG. 17, can be integrated with an
existing gas processing plant where one or more of the existing
subsystems can be utilized. The utilization may arise from the fact
that the existing subsystems are no longer used, or have an
additional capacity available to allow for the integration.
[0159] FIG. 17 shows an exemplary application of an OCM-ETL system
using a PSA system for pre-separations to an existing gas
processing plant, where one or more existing sub systems may be
utilized. As shown in FIG. 17, the existing separations sub-system
can be integrated with the OCM-ETL system to add value by
converting natural gas to higher value liquid hydrocarbons. The PSA
unit can be used to pre-separate the lighter components like
methane, hydrogen, carbon monoxide, carbon dioxide, ethane, and
other components, and the olefin rich stream can be sent to the ETL
reactor that converts the olefins to higher molecular weight liquid
hydrocarbons. One advantage of using a PSA system is the reduction
in net additional feed to the existing separation system, which can
be de-bottlenecked easily. If the separation system is no longer in
use, addition of a PSA can bring about larger total capacities that
can be achieved by adding larger OCM-ETL systems. A natural gas
stream 1720 can be directed to a treatment unit 1701 and then into
a separations system (e.g., cryogenic) 1702. At least portion of a
methane stream 1724 from the separations unit can be directed to an
OCM reactor 1705, while a portion of the methane stream can be
directed to a compressor 1703 and used as sales gas 1721 or other
purposes. A higher hydrocarbon stream can be directed from the
separations system to a C.sub.2 removal unit 1704, which can
produce a natural gas liquids stream 1722 and a C.sub.2 stream
1723. The C.sub.2 stream can be fed into the OCM reactor with the
methane stream and an oxygen stream 1725, and reacted to form
higher hydrocarbon products including ethylene. The OCM product
stream can be directed into a heat recovery system 1706, which can
generate a high pressure superheated (HPSH) steam stream 1726. The
OCM product stream can then be directed to a knockout drum to
recover a condensate stream 1727. The OCM product stream can then
be directed to a compressor 1708, which can operate using the HPSH
steam stream. From the compressor, the OCM product stream can be
directed to a PSA unit 1709. From the PSA unit, light stream
comprising methane, hydrogen, CO and CO.sub.2 can be directed to a
methanation unit 1710, and an olefinic stream can be directed to an
ETL reactor 1711 and reacted to form higher hydrocarbon products.
The ETL product stream can be directed to a heat recovery unit
1712, where boiler feed water (BFW) 1728 can be heated, at least a
portion of which can be fed 1729 to the heat recovery unit 1706.
The ETL product stream can then be directed to another knockout
drum 1713. The overhead stream from the knockout drum can be
directed to a low temperature separations unit 1714, while the
bottoms stream from the knockout drum can be directed to a C.sub.4
removal unit 1715, which can produce a C.sub.4 stream 1730 and a
C.sub.5+ stream 1731. Overhead from the low temperature separations
unit, as well as product from the methanation reactor, can be
directed back to the compressor 1703.
[0160] OCM-ETL systems of the present disclosure can be integrated
into and combined into conventional NGL extraction and NGL
fractionation sections of a midstream gas plant. Where NGLs in the
gas stream are declining (or gas is dry), the deployment of OCM-ETL
can utilize an existing facility to produce additional liquid
streams. The implementation of OCM-ETL can allow for the generation
of on specification "pipeline gas." The products from the facility
can be suitable for use (or on specification or "spec") as pipeline
gas, gasoline product, hydrocarbon (HC) streams with high aromatic
content, and mixed C.sub.4 products. The PSA systems discussed
above can be employed to separate, pre-separate or purify the
hydrocarbon feed streams in the integrated NGL OCM-ETL system. FIG.
18 shows an exemplary NGL extraction facility integrated with an
OCM-ETL system. As shown in FIG. 18, for example, the feed to the
PSA 1802 can be the net incoming gas from the treatment system
1801, which can treat a methane stream (e.g., natural gas) 1810.
The PSA system can separate the feed to the OCM reactor 1803, which
is mostly methane and lighter components with some ethane to
utilize a PBC section of the OCM reactor, and the feed to the ETL
reactor 1805, which can first be processed in a natural gas liquids
extraction system 1804. The feed to the ETL system can be the PSA
tail gas and OCM effluent comprising ethylene, propylene, ethane,
propane, hydrogen, methane, and other components. In some cases,
the OCM effluent can be directly fed to the ETL reactor. In some
cases the OCM effluent is hydrogenated and fed to the ETL system.
In some cases, as shown for example in FIG. 18, the OCM effluent is
fed back to the PSA unit for separation; additional natural gas
1811 can be added, and a stream can be recovered 1812 (e.g., for
use as pipeline gas). In some examples, the system may have a
methanation unit that takes in the effluent from ETL reactor or OCM
reactor and converts the CO, CO.sub.2 and H.sub.2 to methane,
thereby further increasing the carbon efficiency of the process.
The existing NGL extraction and product fractionation 1806
sub-systems can then be used to fractionate the final products,
including into a mixed C.sub.4 stream 1814 and a C.sub.5+ product
stream 1815.
Refining
[0161] Refinery gas typically contains valuable components like
hydrogen, methane, ethane, ethylene, propane, propylene, and
butane. Most commonly, refinery off-gases (ROG) are exported to the
fuel gas system, thereby losing the value of the components
contained therein. The OCM-ETL process can be used to improve the
value of products as the OCM converts the methane to ethylene and
the ETL converts olefins (e.g., those existing in the ROG and those
generated by OCM) to higher value liquids as C.sub.4 components,
gasoline blends, or aromatic components.
[0162] FIG. 19 shows an exemplary PSA unit integrated to a refinery
process scheme. A refinery gas plant 1901 can receive gas 1910 from
cracking or other units. The PSA unit 1903 (after, for example,
treatment of the gas in a treatment unit 1902) can separate
components in refinery gas plant off gas to methane and a C.sub.2+
cut which contains most or all of the olefinic materials. The
methane can be used as refinery fuel 1911 and/or directed to an OCM
unit 1904 with post-bed cracking The OCM feed can be supplemented
with additional natural gas 1912. The olefinic materials can be
directed to an ETL reactor 1905. The OCM effluent can also be
routed to the PSA where the olefins produced in the OCM are also
sent to the ETL reactor. In some cases, the OCM effluent can be
routed to the ETL reactor. In some cases, the OCM effluent may be
hydrogenated before being sent to the PSA unit or ETL reactor. Some
techniques may dictate the use of a cryogenic demethanizer in place
of the PSA, but the application of PSA to pre-separate the refinery
off-gas into a product stream and a tail gas stream containing the
heavier hydrocarbons which is the feed to ETL reactor can result in
significant cost savings. The product stream can contain methane,
ethane, CO, CO.sub.2, and other components, with of each component
from 1 to 99%. A C.sub.3+ stream 1913 from the refinery gas plant
can be directed to a product fractionation system 1906, which can
provide a C.sub.2/C.sub.3 stream 1914 (which can be directed to the
OCM reactor), an iC.sub.4 stream 1915, a gasoline blend stream
1916, and/or a kerosene/jet stream 1917.
[0163] As shown in FIG. 20, in some cases the system can have a
methanation unit to further improve the carbon efficiency of the
process. A refinery gas plant 2001 can receive gas 2010 from
cracking or other units. The PSA unit 2003 (after, for example,
treatment of the gas in a treatment unit 2002) can separate
components in refinery gas plant off gas to methane and a C.sub.2+
cut which contains most or all of the olefinic materials. The
methane can be used as refinery fuel 2011 and/or directed to a
methanation unit 2004, and then to an OCM reactor 2005 with
post-bed cracking The methanation feed can be supplemented with
additional natural gas 2012. The olefinic materials can be directed
to an ETL reactor 2006. The OCM effluent can be routed to the ETL
reactor. In some cases, the OCM effluent can also be routed to the
PSA where the olefins produced in the OCM are also sent to the ETL
reactor. In some cases, the OCM effluent may be hydrogenated before
being sent to the PSA unit or ETL reactor. Some techniques may
dictate the use of a cryogenic demethanizer in place of the PSA,
but the application of PSA to pre-separate the refinery off-gas
into a product stream and a tail gas stream containing the heavier
hydrocarbons which is the feed to ETL reactor can result in
significant cost savings. The product stream can contain methane,
ethane, CO, CO.sub.2, and other components, with of each component
from 1 to 99%. A C.sub.3+ stream 2013 from the refinery gas plant
can be directed to a product fractionation system 2007, which can
provide a C.sub.2/C.sub.3 stream 2014 (which can be directed to the
OCM reactor), an iC.sub.4 stream 2015, a gasoline blend stream
2016, and/or a kerosene/jet stream 2017.
[0164] Methods and systems of the present disclosure can be
combined with or modified by other methods and systems, such as
those described in U.S. patent application Ser. No. 14/591,850,
filed Jan. 7, 2015, now published as U.S. Patent Pub. No
2015/0232395; U.S. patent application Ser. No. 13/936,783, filed
Jul. 8, 2013, now published as U.S. Patent Pub. No. 2014/0012053;
U.S. patent application Ser. No. 13/936,870, filed Jul. 8, 2013,
now published as U.S. Patent Pub. No. 2014/0018589; U.S. patent
application Ser. No. 13/900,898, filed May 23, 2013, now published
as U.S. Patent Pub. No 2014/0107385; U.S. patent application Ser.
No. 14/553,795, filed Nov. 25, 2014, now published as U.S. Patent
Pub. No. 2015/0152025; U.S. patent application Ser. No. 14/592,668,
filed Jan. 8, 2015, now published as U.S. Patent Pub. No.
2015/0210610; and U.S. patent application Ser. No. 14/789,953,
filed Jul. 1, 2015, each of which is entirely incorporated herein
by reference.
[0165] While preferred embodiments of the present invention have
been shown and described herein, it will be obvious to those
skilled in the art that such embodiments are provided by way of
example only. It is not intended that the invention be limited by
the specific examples provided within the specification. While the
invention has been described with reference to the aforementioned
specification, the descriptions and illustrations of the
embodiments herein are not meant to be construed in a limiting
sense. Numerous variations, changes, and substitutions will now
occur to those skilled in the art without departing from the
invention. Furthermore, it shall be understood that all aspects of
the invention are not limited to the specific depictions,
configurations or relative proportions set forth herein which
depend upon a variety of conditions and variables. It should be
understood that various alternatives to the embodiments of the
invention described herein may be employed in practicing the
invention. It is therefore contemplated that the invention shall
also cover any such alternatives, modifications, variations or
equivalents. It is intended that the following claims define the
scope of the invention and that methods and structures within the
scope of these claims and their equivalents be covered thereby.
* * * * *