An apparatus and method of producing methanol includes reacting a heated hydrocarbon-containing gas and an oxygen-containing gas in a reactor; to provide a product stream comprising methanol; and transferring heat from the product stream to the hydrocarbon-containing gas to heat the hydrocarbon cont
An apparatus and method of producing methanol includes reacting a heated hydrocarbon-containing gas and an oxygen-containing gas in a reactor; to provide a product stream comprising methanol; and transferring heat from the product stream to the hydrocarbon-containing gas to heat the hydrocarbon containing gas. After removing methanol and CO2 from the product stream, unprocessed hydrocarbons are mixed with the hydrocarbon containing gas fro reprocessing through the reactor.
대표청구항▼
1. An apparatus for producing methanol, comprising: a reactor having first and second methane-containing gas inputs and an oxygen-containing gas input, said reactor configured to facilitate a multi-stage partial oxidation reaction of heated methane-containing gas by oxygen from an oxygen-containing
1. An apparatus for producing methanol, comprising: a reactor having first and second methane-containing gas inputs and an oxygen-containing gas input, said reactor configured to facilitate a multi-stage partial oxidation reaction of heated methane-containing gas by oxygen from an oxygen-containing gas;a first methane-containing gas supply coupled to the first methane-containing gas input;an oxygen-containing gas supply coupled to the oxygen-containing gas input;a second methane-containing gas supply coupled to the second methane-containing gas input to provide a methane-containing gas to be directly mixed with a mixture of the methane-containing gas and the oxygen-containing gas within the reactor at a later stage of the reaction, wherein said later stage is at a location in said reactor where formation of methanol and formaldehyde is substantially completed; anda condenser in communication with the reactor, the condenser operating at isobaric conditions to reduce product temperature. 2. An apparatus as defined in claim 1, further comprising a heater coupled to the first methane-containing gas supply. 3. An apparatus as defined in claim 1, further comprising a heater and wherein said first and second methane-containing gas supplies are connected with a single source of methane-containing gas; and wherein a portion of the methane-containing gas is taken from the single source to produce the first methane-containing gas supply, while another portion of the methane-containing gas from the single source is the second methane-containing gas supply. 4. An apparatus as defined in claim 1, further comprising a methane-containing gas regulator configured to regulate the quantity a quantity of methanol and a desired quantity of formaldehyde as a result of the reaction in the reactor, by regulating at least one of the first methane-containing gas supply, the second methane-containing gas supply, and the oxygen-containing gas supply. 5. An apparatus as defined in claim 1, further comprising a cooler configured to cool reactor products, and a separator configured to separate a methanol-containing fraction from the reactor products. 6. An apparatus as defined in claim 5, wherein said cooler includes a heat exchanger for exchanging heat between reaction products and the methanol-containing fraction. 7. An apparatus for producing methanol, comprising: a reactor configured to support a reaction of partial oxidation of a first heated hydrocarbon-containing gas with oxygen of an oxygen-containing gas;a first methane-containing gas supply for supplying into the reactor a heated methane-containing gas;an oxygen-containing gas supply for supplying into the reactor the oxygen containing gas;a second methane-containing gas supply, downstream of the first methane-containing gas supply, for supplying into the reactor a cold methane-containing gas having a temperature of less than the heated methane-containing gas, said cold methane-containing gas being directly mixed with a mixture of the methane-containing gas and reaction product containing gas within the reactor to produce a product stream comprising formaldehyde and methanol wherein directly mixing of cold methane-containing gas into reaction products functions to slow oxidation of formaldehyde;a heat exchanger configured to transfer heat from the product stream to the heated methane containing gas; anda condenser in communication with the reactor, the condenser operating at isobaric conditions to reduce product temperature. 8. An apparatus as defined in claim 7, further comprising a heater disposed between the heat exchanger and the reactor, the heater being configured to preheat the heated methane-containing gas. 9. An apparatus as defined in claim 7, wherein said heat exchanger comprises one of a heat exchanger portion of the reactor, an external heat exchanger, or both. 10. The apparatus of claim 9, wherein the heat exchanger comprises an external heat exchanger downstream of the reactor. 11. The apparatus of claim 9, wherein the heat exchanger portion of the reactor comprises a downstream portion of the reactor. 12. An apparatus as in claim 7, wherein said second methane-containing gas supply is arranged at a location of said reactor where formation of methanol and formaldehyde is substantially completed. 13. An apparatus as in claim 7, comprising a controller configured to adjust the second methane-containing gas supply based on one or more operating parameters. 14. An apparatus as in claim 13, wherein the one or more parameters comprise temperature. 15. An apparatus as in claim 7, wherein the condenser is configured to condense a relatively low volatility component of the product stream for separation from a relatively high volatility component of the product stream. 16. An apparatus as in claim 15, comprising a formaldehyde rectifier downstream of the condenser. 17. An apparatus as in claim 15, comprising a methanol rectifier downstream of the condenser. 18. An apparatus as in claim 15 wherein the second methane-containing gas comprises at least one of steam, misted water, CO2, methanol, and formaldehyde. 19. An apparatus for producing methanol, comprising: a reactor having first input and a coolant input and an oxygen-containing gas input, said reactor configured to facilitate a partial oxidation reaction of heated methane-containing gas by oxygen from an oxygen-containing gas into methanol and formaldehyde;a first methane-containing gas supply coupled to the first input;an oxygen-containing gas supply coupled to the oxygen-containing gas input;a coolant supply coupled to the coolant input, wherein gas from the coolant supply is directly mixed with a mixture of the methane-containing gas and the oxygen-containing gas within the reactor at a later stage of the reaction; anda condenser in communication with the reactor, the condenser operating at isobaric conditions to reduce product temperature. 20. An apparatus as defined in claim 19, further comprising a heater coupled to the first methane-containing gas supply. 21. An apparatus as defined in claim 19, further comprising a heater and wherein said first methane-containing gas supply and coolant gas supply are connected with a single source of a hydrocarbon-containing gas; and wherein a portion of the hydrocarbon-containing gas is taken from the single source to produce the first gas supply, while another portion of the hydrocarbon-containing gas from the single source is a second gas supply. 22. An apparatus as defined in claim 19, wherein said later stage is at a location of said reactor where formation of methanol and formaldehyde is substantially completed. 23. An apparatus as defined in claim 19, further comprising a gas regulator configured to regulate a quantity of methanol and quantity of formaldehyde as a result of the reaction in the reactor, by regulating at least one of the first methane-containing gas supply, the coolant supply, and the oxygen-containing gas supply. 24. An apparatus as defined in claim 19, wherein the coolant supply supplies a gas selected from the group of steam, misted water, CO2, methane, methanol, formaldehyde, and combinations thereof. 25. An apparatus as defined in claim 24, wherein a cooler includes a heat exchanger for exchanging heat between reaction products and a methanol-containing fraction. 26. An apparatus for producing methanol, comprising: a reactor configured to support a partial oxidation reaction of a first heated methane-containing gas with oxygen of an oxygen-containing gas;a first methane-containing gas supply for supplying into the reactor a heated methane-containing gas; an oxygen-containing gas supply operatively coupled to the reactor;a coolant supply, downstream of the first methane-containing gas supply, for supplying into the reactor a coolant with a temperature lower than the temperature of the heated methane-containing gas, said coolant being directly mixed with a mixture of the methane-containing gas and reaction product containing gas within the reactor to produce a product stream comprising formaldehyde and methanol wherein mixing the coolant into product stream functions to slow decomposition of formaldehyde; anda condenser in communication with the reactor, the condenser operating at isobaric conditions to reduce product temperature. 27. An apparatus as defined in claim 26, further comprising a heat exchanger configured to transfer heat from the product stream to the methane-containing gas supplied by the first methane-containing gas supply and a heater disposed between the heat exchanger and the reactor, the heater being configured to preheat the methane-containing gas. 28. An apparatus as defined in claim 26, wherein said coolant supply supplies a gas selected from the group consisting of steam, misted water, CO2, methane, methane, methanol, formaldehyde, and combinations thereof. 29. The apparatus of claim 26, wherein said coolant comprises a reaction product from the reactor. 30. The apparatus of claim 29 wherein heat from said reaction product is transferred to said first methane-containing gas prior to transfer into the reactor. 31. An apparatus as in claim 26, wherein said coolant supply is arranged at a location of said reactor where formation of methanol and formaldehyde is substantially completed. 32. An apparatus as in claim 26, comprising a controller configured to adjust an amount of coolant supplied from said coolant supply based on one or more operating parameters. 33. An apparatus as in claim 32, wherein the one or more parameters comprise temperature. 34. An apparatus as in claim 26, wherein the condenser is configured to condense a relatively low volatility component of the product stream for separation from a relatively high volatility component of the product stream. 35. An apparatus as in claim 34, comprising a formaldehyde rectifier downstream of the condenser. 36. An apparatus as in claim 34, comprising a methanol rectifier downstream of the condenser.
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이 특허에 인용된 특허 (100)
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