Feed natural gas

In this process, the feed (natural gas) is pyrolyzed in preheated furnaces lined with a checker work of hot bricks. The pyrolysis reaction produces carbon, which collects on the bricks. The cooled bricks are then... 

For natural-gas-fuelled CHP plants, the same line of argumentation holds as for the stationary use of hydrogen from biomass. It is more reasonable to use natural gas directly than to convert it to hydrogen first and then to heat and electricity. High electrical efficiencies can be reached in the stationary sector by feeding natural gas to molten-carbonate fuel cells (MCFC) and solid-oxide fuel cells (SOFC). Molten-carbonate fuel cells have the added advantage of using C02 for the electrolyte (see also Chapter 13). 

C. Soaking Phase. The soaking phase takes place in the rest of the reactor, where the gas is at high temperature. Minor changes in gas composition occur due to secondary reactions of methane and carbon. As the reaction rates are relatively low, the methane content is higher than would be expected from equilibrium. During the soaking phase, a portion of the carbon also disappears by reactions with CO2 and steam. However, some carbon is always present in the product gas from the reactor in a quantity equivalent to about 1-3% wt of the oil feed. Natural gas feedstock produces only a very small amount of residual carbon i.e., about 0.02% wt of the gas feedstock. 

The flue gas generated in the tubular reformer is used for preheat of reformer and prereformer feed, natural gas preheat, steam superheat and preheat of combustion air. The synthesis gas generated in the tubular reformer is cooled by high-pressure steam generation (4), preheat of boiler feed water and reboiling in the distillation section (5). 

Although the attractiveness of the projects is case specific as it depends on the plant capacity, unit location and local investment requirements, cost of the feed natural gas, scope of the project (whether only olefins or all the way to polyolefins), etc. on the average MTO or GTP (gas-to-polymers) projects provide returns on investment in the order of 20-25%. 

Figure 5.4 shows a schematic of the Ciyoplus process [76] for the removal of nonhydrocarbon contaminants, and Figure 5.5 shows a flow diagram of the Costain nitrogen removal process [77], The Costain double-column process is sufficiently flexible to handle natural gas with nitrogen concentrations of 5—80 mol%. Feed natural gas above 27 bar can be directly processed without any compression. 

Feeds Natural gas Light naphtha Heavy fuel Residue under vacuum Asphalt... 

Process Feed Natural Gas Composition (dry outlet gas) Butane Naphtha... 

Methanol. If methanol is to compete with conventional gasoline and diesel fuel it must be readily available and inexpensively produced. Thus methanol production from a low-cost feed stock such as natural gas [8006-14-2] or coal is essential (see Feedstocks). There is an abundance of natural gas (see Gas, natural) woddwide and reserves of coal are even greater than those of natural gas. 

The process can be operated in two modes co-fed and redox. The co-fed mode employs addition of O2 to the methane/natural gas feed and subsequent conversion over a metal oxide catalyst. The redox mode requires the oxidant to be from the lattice oxygen of a reducible metal oxide in the reactor bed. After methane oxidation has consumed nearly all the lattice oxygen, the reduced metal oxide is reoxidized using an air stream. Both methods have processing advantages and disadvantages. In all cases, however, the process is mn to maximize production of the more desired ethylene product. 

Absorber oil units offer the advantage that Hquids can be removed at the expense of only a small (34—69 kPa (4.9—10.0 psi)) pressure loss in the absorption column. If the feed gas is available at pipeline pressure, then Httle if any recompression is required to introduce the processed natural gas into the transmission system. However, the absorption and subsequent absorber-oil regeneration process tends to be complex, favoring the simpler, more efficient expander plants. Separations using soHd desiccants are energy-intensive because of the bed regeneration requirements. This process option is generally considered only in special situations such as hydrocarbon dew point control in remote locations. 

The separation of nitrogen from natural gas reHes on the differences between the boiling points of nitrogen (77.4 K) and methane (91.7 K) and involves the cryogenic distillation of a feed stream that has been preconditioned to very low levels of carbon dioxide, water vapor, and other constituents that would form soHds at the low processing temperatures. 

Butanes are recovered from raw natural gas and from petroleum refinery streams that result from catalytic cracking, catalytic reforming, and other refinery operations. The most common separation techniques are based on a vapor—Hquid, two-phase system by which Hquid butane is recovered from the feed gas. 

Steam Reforming. In steam reforming, light hydrocarbon feeds ranging from natural gas to straight mn naphthas are converted to synthesis gas (H2, CO, CO2) by reaction with steam (qv) over a catalyst in a primary reformer furnace. This process is usually operated at 800—870°C and 2.17—2.86... 

Naphtha at one time was a more popular feed, and alkah-promoted catalysts were developed specifically for use with it. As of 1994 the price of naphtha in most Western countries is too high for a reformer feed, and natural gas represents the best economical feedstock. However, where natural gas is not available, propane, butane, or naphtha is preferentially selected over fuel oil or coal. 

Naphtha desulfurization is conducted in the vapor phase as described for natural gas. Raw naphtha is preheated and vaporized in a separate furnace. If the sulfur content of the naphtha is very high, after Co—Mo hydrotreating, the naphtha is condensed, H2S is stripped out, and the residual H2S is adsorbed on ZnO. The primary reformer operates at conditions similar to those used with natural gas feed. The nickel catalyst, however, requires a promoter such as potassium in order to avoid carbon deposition at the practical levels of steam-to-carbon ratios of 3.5—5.0. Deposition of carbon from hydrocarbons cracking on the particles of the catalyst reduces the activity of the catalyst for the reforming and results in local uneven heating of the reformer tubes because the firing heat is not removed by the reforming reaction. 

The soaking phase takes place in the rest of the reactor where the gas is at high temperatures. A portion of the carbon disappears by reactions with CO2 and steam. Some carbon, about 1—3 wt % of the oil feed, is present in the product gas. Natural gas feedstock produces only about 0.02 wt % of carbon. 

The Calcimatic is a patented kiln of Canadian origin that is radically different from other kiln types. It consists of a circular traveling hearth of variable speed, supported on two concentric tiers of rollers. Kiln feed of 12.7 mm is fed onto the hearth in a 2.5—10 cm bed from a preheater chamber. The kiln is usually fired with natural gas or fuel oil, although the option of using pulverized coal has also been developed. After great interest, resulting in sales of many units throughout the world, the popularity of the Calcimatic has ebbed because of disappointment in the unit s mediocre thermal efficiency. 

The hydrocarbon cracking operations that generate feed olefins generally do not produce sufficient isobutane to satisfy the reaction requirements. Additional isobutane must be recovered from cmde oil or natural gas Hquids or generated by other refinery operations. A growing quantity of isobutane is produced by the isomerization of / -butane [106-97-8]. 

Of the raw material hydrogen sources—natural gas, coal, and petroleum fractions—natural gas is the most often employed in ammonia plants in the 1990s and steam reforming is by far the most often used process. Partial oxidation processes are utilized where steam-reformable feeds are not available or in special situations where local conditions exist to provide favorable economics. Table 5 fists the contribution of the various feedstocks to world ammonia... 

Heavy Hydrocarbon-Based Partial Oxidation Processes. Two major partial oxidation processes are commercially available, the SheU process (38) and the Texaco process (39). Operating conditions in the gas generator vary from 1200°C to 1370°C and from 3100 kPa to 8270 kPa (450—1200 psig). Generally, heavy oils are the hydrocarbon feeds however, the process can also accommodate feeds from natural gas to residual oils. 

Feed Ga.s Purifica.tion. Because nickel-based reforming catalysts are quite sensitive to sulfur, halogen, and heavy metal poisons which may be found ia natural gas, a feedstock purification system is normally required. Sulfur compounds, ia both organic and inorganic forms, are the most common... 

Chlorides may be found in natural gas, particularly associated with offshore reservoirs. Modified alumina catalysts have been developed to irreversibly absorb these poisons from the feed gas. 

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