Reactors and systems for oxidative coupling of methane
원문보기
IPC분류정보
국가/구분
United States(US) Patent
등록
국제특허분류(IPC7판)
C07C-002/78
B01J-008/18
B01J-008/02
출원번호
US-0553795
(2014-11-25)
등록번호
US-10047020
(2018-08-14)
발명자
/ 주소
Cizeron, Joel
Radaelli, Guido
Lakhapatri, Satish
Freer, Erik
Hong, Jin Ki
McCormick, Jarod
Sheridan, David
Reid, Charles
Pellizzari, Roberto
Weinberger, Samuel
Edwards, Justin Dwight
출원인 / 주소
SILURIA TECHNOLOGIES, INC.
대리인 / 주소
Wilson Sonsini Goodrich & Rosati
인용정보
피인용 횟수 :
0인용 특허 :
225
초록▼
In an aspect, the present disclosure provides a method for the oxidative coupling of methane to generate hydrocarbon compounds containing at least two carbon atoms (C2+ compounds). The method can include mixing a first gas stream comprising methane with a second gas stream comprising oxygen to form
In an aspect, the present disclosure provides a method for the oxidative coupling of methane to generate hydrocarbon compounds containing at least two carbon atoms (C2+ compounds). The method can include mixing a first gas stream comprising methane with a second gas stream comprising oxygen to form a third gas stream comprising methane and oxygen and performing an oxidative coupling of methane (OCM) reaction using the third gas stream to produce a product stream comprising one or more C2+ compounds.
대표청구항▼
1. A method for the oxidative coupling of methane to generate hydrocarbon compounds containing at least two carbon atoms (C2+ compounds), comprising: (a) mixing a first gas stream comprising methane with a second gas stream comprising oxygen to form a third gas stream comprising methane and oxygen,
1. A method for the oxidative coupling of methane to generate hydrocarbon compounds containing at least two carbon atoms (C2+ compounds), comprising: (a) mixing a first gas stream comprising methane with a second gas stream comprising oxygen to form a third gas stream comprising methane and oxygen, wherein along a direction that is orthogonal to a direction of flow of said third gas stream, (i) a temperature of said third gas stream varies by less than 10° C., (ii) a ratio of a concentration of said methane to a concentration of said oxygen (CH4/O2) in said third gas stream varies by less than 10%, and/or (iii) a flow rate of said third gas stream varies by less than 5%; and(b) performing an oxidative coupling of methane (OCM) reaction using said third gas stream to produce a product stream comprising one or more C2+ compounds. 2. The method of claim 1, further comprising separating said product stream into at least a fourth stream and a fifth stream, wherein said fourth stream has a lower C2+ concentration than said fifth stream, wherein said fifth stream has a higher C2+ concentration than said product stream. 3. The method of claim 1, wherein (a) comprises any two of (i)-(iii). 4. The method of claim 1, wherein (a) comprises (i), (ii) and (iii). 5. A method for the oxidative coupling of methane to generate hydrocarbon compounds containing at least two carbon atoms (C2+ compounds), comprising: (a) in a mixer, mixing a first gas stream comprising methane with a second gas stream comprising oxygen to form a third gas stream comprising methane and oxygen, wherein said third gas stream has a composition that is selected such that at most 5% of said oxygen in said third gas stream auto-ignites; and(b) performing an oxidative coupling of methane (OCM) reaction using said third gas stream to produce a product stream comprising one or more C2+ compounds. 6. A method for the oxidative coupling of methane to generate hydrocarbon compounds containing at least two carbon atoms (C2+ compounds), the method comprising: (a) in a mixer, mixing a first gas stream comprising methane with a second gas stream comprising oxygen to form a third gas stream comprising methane and oxygen; and(b) within a time period less than an auto-ignition delay time of oxygen and methane in said third gas stream, performing an oxidative coupling of methane (OCM) reaction using said third gas stream to produce a product stream comprising one or more C2+ compounds. 7. A method for producing at least one C2+ alkene, comprising: (a) directing methane and an oxidizing agent into a reactor comprising a catalyst unit and a cracking unit downstream of said catalyst unit, wherein said catalyst unit comprises an oxidative coupling of methane (OCM) catalyst that facilitates an OCM reaction;(b) in said catalyst unit, reacting said methane and said oxidizing agent with the aid of said OCM catalyst to generate at least one OCM product comprising at least one C2+ compound;(c) directing said at least one OCM product as part of a hydrocarbon-containing stream through said cracking unit, which hydrocarbon-containing stream comprises at least one C2+ alkane; and(d) in said cracking unit, cracking said at least one C2+ alkane to yield a product stream comprising said at least one C2+ alkene,wherein said cracking unit is operated at a (i) hydrocarbon-containing stream residence time and (ii) cracking unit temperature profile selected such that a ratio of C2+ alkene to C2+ alkane in said product stream is greater than 0.1. 8. The method of claim 7 wherein said OCM catalyst is a nanowire catalyst. 9. The method of claim 7, wherein said oxidizing agent is O2. 10. The method of claim 7, wherein said at least one C2+ compound comprises said at least one C2+ alkane. 11. The method of claim 7, wherein in (c), at least a portion of said at least one C2+ alkane is provided from a source external to said reactor. 12. The method of claim 11, wherein said source is a natural gas liquids source. 13. The method of claim 7, wherein said at least one C2+ alkane comprises a plurality of C2+ alkanes. 14. The method of claim 13, wherein said plurality of C2+ alkanes are each directed into said cracking unit at different locations. 15. The method of claim 7, wherein said cracking is conducted with the aid of heat generated in said OCM reaction. 16. The method of claim 7, wherein said cracking unit is operated adiabatically. 17. The method of claim 7, wherein said hydrocarbon-containing stream is directed through said cracking unit at a residence time that is less than or equal to 1 second. 18. The method of claim 7, wherein said residence time is less than or equal to 500 milliseconds. 19. The method of claim 7, wherein said temperature profile is from about 750° C. to 950° C. 20. The method of claim 7, wherein said cracking unit has an inlet and an outlet downstream of said inlet, where said hydrocarbon-containing stream is directed from said inlet to said outlet, and wherein said inlet is at a temperature from about 880° C. to 950° C. and said outlet is at a temperature from about 750° C. to 880° C. 21. The method of claim 7, wherein said ratio is greater than 1. 22. The method of claim 21, wherein said ratio is greater than 3. 23. The method of claim 22, wherein said ratio is greater than 5. 24. A method for producing at least one C2+ alkene, comprising: (a) directing methane and an oxidizing agent into a reactor comprising a catalyst unit and a cracking unit downstream of said catalyst unit, wherein said catalyst unit comprises an oxidative coupling of methane (OCM) catalyst that facilitates an OCM reaction;(b) in said catalyst unit, reacting said methane and said oxidizing agent with the aid of said OCM catalyst to generate at least one OCM product comprising at least one C2+ compound;(c) directing said at least one OCM product as part of a hydrocarbon-containing stream through said cracking unit from an inlet to an outlet at a residence time that is less than 500 milliseconds at a reactor diameter of at least about 12 inches, wherein said inlet is at a temperature from about 800° C. to 950° C. and said outlet is at a temperature from about 700° C. to 950° C., and wherein said hydrocarbon-containing stream comprises at least one C2+ alkane; and(d) in said cracking unit, cracking said at least one C2+ alkane to yield a product stream comprising said at least one C2+ alkene. 25. A method, comprising: (a) providing a reactor comprising (i) an OCM section comprising an OCM catalyst that facilitates formation of OCM products from methane and an oxidizing agent, and (ii) a post-bed cracking section located downstream of said OCM catalyst section that facilitates cracking of at least a portion of said OCM products, wherein said OCM section and said post-bed cracking section are integrated in said reactor;(b) directing said methane and said oxidizing agent to said OCM section;(c) conducting OCM in said OCM section to generate said OCM products;(d) mixing said OCM products with a CO2 stream to produce a cracking stream; and(e) cracking at least a portion of said OCM products in said cracking stream in said post-bed cracking section. 26. The method of claim 24, wherein said at least one C2+ compound comprises said at least one C2+ alkane. 27. The method of claim 24, wherein said at least one C2+ alkane comprises a plurality of alkanes. 28. The method of claim 27, wherein said plurality of alkanes comprises ethane, propane, butane, or a combination thereof. 29. The method of claim 27, wherein at least a portion of said plurality of alkanes is provided by a source external to said reactor. 30. The method of claim 29, further comprising directing said plurality of alkanes into said cracking unit sequentially based on respective carbon numbers of each of said plurality of alkanes. 31. The method of claim 29, further comprising directing said plurality of alkanes into said cracking unit at different locations along a length of said cracking unit based on respective carbon numbers of each of said plurality of alkanes. 32. The method of claim 29, further comprising directing said plurality of alkanes into said cracking unit at different temperatures based on respective carbon numbers of each of said plurality of alkanes. 33. The method of claim 25, wherein residence time in said post-bed cracking section is at least about 10 times shorter than residence time in said OCM section. 34. The method of claim 25, wherein residence time in said post-bed cracking section is less than or equal to about 200 milliseconds. 35. The method of claim 25, wherein said OCM section is operated isothermally and said post-bed cracking section is operated adiabatically. 36. The method of claim 25, further comprising introducing an alkane stream external to said reactor into said post-bed cracking section. 37. The method of claim 36, further comprising preheating said alkane stream to a temperature of at least about 550° C. prior to introducing said alkane stream into said post-bed cracking section.
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