Method and plant for production of oxygenated hydrocarbons

• US 6,794,418 B2
• Filed: 10/08/2002
• Issued: 09/21/2004
• Est. Priority Date: 12/28/1999
• Status: Expired due to Fees

• Current Assignee: Statoil ASA (Asa Equinor)
• Original Assignee: Statoil ASA (Asa Equinor)
• Inventors: Bahr, Linda, Veland, Bjørn Jarle, Sogge, Jostein, Olsvik, Ola
• Primary Examiner(s): Parsa, J.
• Application Number:
  US10/169,420
• Publication Number:
  US 20030092780A1
• Time in Patent Office: 714 Days
• Field of Search: 518/700, 518/702, 518/703, 518/704, 518/705, 518/706
• US Class Current: 518/706
• CPC Class Codes: C01B 2203/0233 the reforming step being a steam reforming step
• CPC Class Codes: C01B 2203/0244 the reforming step being an autothermal reforming step, e.g. secondary reforming processes
• CPC Class Codes: C01B 2203/0255 containing a non-catalytic partial oxidation step
• CPC Class Codes: C01B 2203/0405 Purification by membrane separation
• CPC Class Codes: C01B 2203/043 Regenerative adsorption process in two or more beds, one for adsorption, the other for regeneration
• CPC Class Codes: C01B 2203/046 Purification by cryogenic separation
• CPC Class Codes: C01B 2203/048 the impurity being an organic compound
• CPC Class Codes: C01B 2203/06 Integration with other chemical processes
• CPC Class Codes: C01B 2203/061 Methanol production
• CPC Class Codes: C01B 2203/0811 by combustion of fuel
• CPC Class Codes: C01B 2203/0816 Heating by flames
• CPC Class Codes: C01B 2203/0822 the fuel containing hydrogen
• CPC Class Codes: C01B 2203/0827 at least part of the fuel being a recycle stream
• CPC Class Codes: C01B 2203/0844 the non-combustive exothermic reaction being another reforming reaction as defined in groups C01B2203/02 - C01B2203/0294
• CPC Class Codes: C01B 2203/0866 by combination of different heating methods
• CPC Class Codes: C01B 2203/0883 by indirect heat exchange
• CPC Class Codes: C01B 2203/1241 Natural gas or methane
• CPC Class Codes: C01B 2203/141 At least two reforming, decomposition or partial oxidation steps in parallel
• CPC Class Codes: C01B 2203/142 At least two reforming, decomposition or partial oxidation steps in series
• CPC Class Codes: C01B 2203/143 Three or more reforming, decomposition or partial oxidation steps in series
• CPC Class Codes: C01B 2203/148 : involving a recycle stream to the feed of the process for making hydrogen or synthesis gas
• CPC Class Codes: C01B 2203/82 : Several process steps of C01B2203/02 - C01B2203/08 integrated into a single apparatus
• CPC Class Codes: C01B 3/36 : using oxygen or mixtures containing oxygen as gasifying agents
• CPC Class Codes: C01B 3/382 : Multi-step processes
• CPC Class Codes: C01B 3/56 : by contacting with solids; Regeneration of used solids C01B3/508 takes precedence
• CPC Class Codes: C07C 29/1518 : one step being the formation of initial mixture of carbon oxides and hydrogen for synthesis
• CPC Class Codes: C07C 31/04 : Methanol
• CPC Class Codes: C07C 41/01 : Preparation of ethers
• CPC Class Codes: C07C 43/043 : Dimethyl ether
• CPC Class Codes: Y02P 20/10 : Process efficiency

Abstract

A method for increasing production in an existing processing plant for converting natural gas into a product, wherein the natural gas is first converted into a synthesis gas in a synthesis gas section, the synthesis gas is reacted in a reactor for synthesis of the product, where non-converted synthesis gas and product are separated into two streams, where a product-rich stream is taken out of the process, while a product-poor stream is recycled as feed to the reactor together with make-up synthesis gas, and where a portion of the recycle stream is taken out of the recycle loop as a purge gas, where the purge gas is separated into hydrogen-rich and hydrogen-poor streams, where hydrogen-rich streams are introduced into steps in the process where it is desirable to have a supplement of hydrogen, and where the residual thermal value of the hydrogen-poor stream is optionally used for heating before it is discharged. A modified processing plant for carrying out the method is also described.

Claims

1. A method for increasing production in an existing process plant for converting natural gas to a product, comprising:

converting the natural gas into a synthesis gas in a synthesis gas section, the synthesis gas being reacted in a reactor for synthesis of the product;

separating non-converted synthesis gas and product into a product-rich stream and a product poor stream;

removing the product-rich stream from the process;

recycling the product-poor stream as feed in a recycle loop to the reactor together with make-up synthesis gas;

removing a portion of the recycle stream from the recycle loop as a purge gas;

separating the purge gas into a hydrogen-rich stream and a hydrogen-poor stream, the hydrogen-rich stream being introduced into the process plant where it is desirable to have a supplement of hydrogen; and

feeding the synthesis gas with the hydrogen-rich stream as a hydrogen-enriched synthesis gas from the separated purge gas, the hydrogen-enriched synthesis gas being passed through a once-through reactor for production of the product and through a unit in order to separate the product-rich stream and the product-poor stream.

2. The method accordingly to claim 1, wherein the residual thermal value in the hydrogen-poor stream is used for heating before it is discharged.

3. The method according to claim 1, wherein the product-poor stream is fed with additional synthesis gas which is produced in a separate secondary synthesis gas line.

4. The method according to claim 1, wherein the reactor is an existing reactor in the process plant and is operated virtually unchanged.

5. The method according to claim 2, wherein the reactor is an existing reactor in the process plant and is operated virtually unchanged.

6. The method according to claim 3, wherein the reactor is an existing reactor in the process plant and is operated virtually unchanged.

7. The method according to claim 1, wherein the converting of the synthesis gas is based on one of ATR and POX.

8. The method according to claim 2, wherein the converting of the synthesis gas is based on one of ATR and POX.

9. The method according to claim 3, wherein the converting of the synthesis gas is based on one of ATR and POX.

10. The method according to claim 1, wherein the product is one of methanol and dimethyl ether.

11. The method according to claim 2, wherein the product is one of methanol and dimethyl ether.

12. The method according to claim 3, wherein the product is one of methanol and dimethyl ether.

13. A processing plant for producing a product on the basis of natural gas, comprising:

a synthesis gas section;

a synthesis section in communication with the synthesis gas section that is arranged to form the product;

a purification section in communication with the synthesis section and arranged such that the product is separated from unconverted reactants and other substances and purified, and wherein unconverted reactants that are separated from the product are recycled to the synthesis section, and where at least a portion of the gas that is recycled is drawn off;

a separation unit arranged to separate the gas that is drawn off into hydrogen-rich and hydrogen-poor fractions;

the hydrogen-rich fractions leading into the natural gas feed and for recycling to the synthesis section; and

a once-through reactor for synthesis of the product, wherein feeding the synthesis gas with the hydrogen-rich fraction as a hydrogen-enriched synthesis gas from the drawn off gas, the hydrogen-enriched synthesis gas is passed through the once-through reactor for production of the product and through a unit to separate a product-rich fraction and a product-poor fraction.

14. The processing plant of claim 13, further comprising a line for conveying hydrogen-poor fractions for combustion.

15. The processing plant according to claim 13 further comprising a separate secondary synthesis gas line for producing a secondary synthesis gas, and a line to lead the secondary synthesis gas as feed for the synthesis section.