Methane Conversion Apparatus and Process Using a Supersonic Flow Reactor

Abstract

Apparatus and methods are provided for converting methane in a feed stream to acetylene. A hydrocarbon stream is introduced into a supersonic reactor and pyrolyzed to convert at least a portion of the methane to acetylene. The reactor effluent stream may be treated to convert acetylene to another hydrocarbon process.

1 . An apparatus for producing acetylene from a feed stream comprising methane comprising:
 a supersonic reactor for receiving the methane feed stream and heating the methane feed stream to a pyrolysis temperature to produce an effluent;   a reactor shell of the supersonic reactor for defining a reactor chamber;   a combustion zone of the supersonic reactor for combusting a fuel source to provide a high temperature carrier gas passing through the reactor space at supersonic speeds to heat and accelerate the methane feed stream to a pyrolysis temperature; and   a heat exchanger for transferring heat from at least a portion of at least one of a pyrolysis stream and an effluent stream to at least one other portion of the process stream.   
     
     
         2 . The apparatus of  claim 1 , wherein the heat exchanger comprises a ceramic tube heat exchanger. 
     
     
         3 . The apparatus of  claim 2 , wherein the ceramic tube comprises a material selected from the group consisting of a carbide, a nitride, titanium diboride, a sialon ceramic, zirconia, or thoria. 
     
     
         4 . The apparatus of  claim 1 , wherein the heat exchanger includes coated highly-inert tubes to restrict corrosion thereof. 
     
     
         5 . The apparatus of  claim 4 , wherein the coated highly-inert tubes include highly-sulfided tubes. 
     
     
         6 . The apparatus of  claim 4 , wherein the coated highly-inert tubes include carbon-coated tubes. 
     
     
         7 . The apparatus of  claim 1 , wherein the heat exchanger comprises a superalloy tube heat exchanger. 
     
     
         8 . The apparatus of  claim 7 , wherein the superalloy tube heat exchanger comprises at least one of nickel-based high-temperature low creep superalloy and chromium. 
     
     
         9 . The apparatus of  claim 1 , wherein the heat exchanger provides heat to a circulating heat exchange fluid. 
     
     
         10 . The apparatus of  claim 9 , wherein the circulating heat exchange fluid comprises a fluid selected from the group consisting of water, steam, super-heated steam, and a hydrocarbon heat transfer fluid. 
     
     
         11 . The apparatus of  claim 10 , further comprising a hot oil loop, and
 wherein the circulating heat exchange fluid comprises a hydrocarbon heat transfer fluid providing at least a portion of the hot oil loop.   
     
     
         12 . The apparatus of  claim 9 , wherein the heat exchange fluid comprises water preheated to its bubble point. 
     
     
         13 . The apparatus of  claim 1 , wherein the heat exchanger comprises a plurality of heat exchangers in series to produce steam streams of varying grades. 
     
     
         14 . The apparatus of  claim 13 , further comprising a power generation device, and
 wherein at least one steam stream is provided to a power generation device to generate power therefrom.   
     
     
         15 . The apparatus of  claim 1 , wherein the heat exchanger is a stab-in heat exchanger with a heat transfer fluid flowing therethrough. 
     
     
         16 . The apparatus of  claim 15 , wherein the heat transfer fluid is selected from the group consisting of molten metal, VSO heat exchanger fluid, raising steam, superheating steam, hot oil, and liquid sodium. 
     
     
         17 . The apparatus of  claim 1 , wherein the heat exchanger includes a phase transformation fluid capable of transferring energy from portions of the effluent stream. 
     
     
         18 . The apparatus of  claim 1 , wherein the heat exchanger fluid includes undergoes a transformation, including at least one of a eutectic-eutectic fluid transformation and eutectic solid-liquid transformation of a composition for transferring energy from the portion of the effluent stream. 
     
     
         19 . An apparatus for producing acetylene from a feed stream comprising methane comprising:
 a supersonic reactor for receiving the methane feed stream and heating the methane feed stream to a pyrolysis temperature to produce an effluent;   a reactor shell of the supersonic reactor for defining a reactor chamber;   a combustion zone of the supersonic reactor for combusting a fuel source to provide a high temperature carrier gas passing through the reactor space at supersonic speeds to heat and accelerate the methane feed stream to a pyrolysis temperature; and   a heat exchanger for transferring heat from at least a portion of at least one of a pyrolysis stream and an effluent stream.   
     
     
         20 . The apparatus of  claim 19 , wherein the heat exchanger comprises a transport bed heat exchanger with direct contact between the at least one of the pyrolysis stream and the effluent stream and a bulk solid. 
     
     
         21 . The apparatus of  claim 19 , wherein the heat exchanger comprises a transport bed heat exchanger with indirect contact between the at least one of the pyrolysis stream and the effluent stream and a bulk solid through a component of the heat exchanger. 
     
     
         22 . The apparatus of  claim 19 , wherein the heat exchanger includes a high temperature thermoelectric heat exchanger for generating electricity