Method and system for producing methanol using an integrated oxygen transport membrane based reforming system

• US 9,839,899 B2
• Filed: 02/15/2016
• Issued: 12/12/2017
• Est. Priority Date: 04/26/2013
• Status: Active Grant

• Current Assignee: Praxair Technology Incorporated (Linde Plc)
• Original Assignee: Praxair Technology Incorporated (Linde Plc)
• Inventors: Stuckert, Ines C., Chakravarti, Shrikar, Drnevich, Raymond F.
• Primary Examiner(s): SEIFU, LESSANEWORK T
• Application Number:
  US15/043,867
• Publication Number:
  US 20160158723A1
• Time in Patent Office: 666 Days
• CPC Class Codes: B01J 12/00 Chemical processes in general for reacting gaseous media with gaseous media; Apparatus specially adapted therefor B01J3/08, B01J8/00, B01J19/08 take precedence
• CPC Class Codes: B01J 19/2475 Membrane reactors
• CPC Class Codes: B01J 8/067 Heating or cooling the reactor B01J8/062 takes precedence
• CPC Class Codes: C01B 13/0251 by making use of membranes
• 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 2203/0283 containing a CO-shift step, i.e. a water gas shift 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 2203/061 Methanol production
• CPC Class Codes: C01B 2203/0805 Methods of heating the process for making hydrogen or synthesis gas
• CPC Class Codes: C01B 2203/0894 Generation of steam
• CPC Class Codes: C01B 2203/1258 Pre-treatment of the feed
• CPC Class Codes: C01B 2203/142 At least two 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 3/384 the catalyst being continuously externally heated
• 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

Abstract

A method and system for producing methanol that employs an integrated oxygen transport membrane based reforming system is disclosed. The integrated oxygen transport membrane based reforming system carries out a primary reforming process, a secondary reforming process, and synthesis gas conditioning to produce synthesis gas having a desired module of between about 2.0 and 2.2 for a methanol production process thereby optimizing the efficiency and productivity of the methanol plant.

Claims

1. A system for producing methanol using an oxygen transport membrane based reforming system comprising:

an oxygen transport membrane based reforming system configured to reform a combined feed stream of natural gas and steam to produce a synthesis gas stream, wherein said system comprises at least one reforming reactor and at least one oxygen transport membrane reactor in close proximity to said at least one reforming reactor, wherein the oxygen transport membrane reactor comprises one or more oxygen transport membrane tubes wherein said tubes contain both a combustion catalyst and a reforming catalyst disposed therein;

a module management system configured to produce a supplemental hydrogen stream from a portion of the produced synthesis gas stream or a portion of a methanol purge stream or both, and wherein a portion of the supplemental hydrogen stream is combined with the produced synthesis gas stream to yield a modified synthesis gas product stream having a module between about 2.0 to 2.2;

a duct burner disposed within or proximate to the oxygen transport membrane based reforming system, wherein the duct burner is configured to combust a supplemental fuel stream wherein a portion of said supplemental fuel stream is comprised of synthesis gas generated by the module management system;

a methanol synthesis reactor configured to receive the modified synthesis gas product stream and produce crude methanol and the methanol purge stream; and

a methanol purification system configured to purify the crude methanol.

2. The system of claim 1 wherein a portion of the supplemental hydrogen stream is combined with the combined feed stream.

3. The system of claim 1 wherein the oxygen transport membrane reactor comprises one or more oxygen transport membrane tubes, wherein said tubes are configured as multilayered dual phase ceramic tubes capable of conducting oxygen ions at an elevated operational temperature.

4. The system of claim 3 wherein said multilayered dual phase ceramic tubes comprise a dense layer, a porous support and an intermediate porous layer capable of conducting oxygen ions at an elevated operational temperature.

5. The system of claim 4 wherein said combustion catalyst is disposed in or proximate to the porous support layer of said ceramic tubs and proximate to the permeate side of the oxygen transport membrane tubes to facilitate reaction of a portion of the reformed synthesis gas stream contacting the permeate side of the oxygen transport membrane tubes with the permeated oxygen stream.

6. The system of claim 5 wherein the retentate side of the oxygen transport membrane tubes is the exterior surface of the ceramic tubes exposed to the heated oxygen containing stream and the permeate side is the interior surface of the ceramic tubes.