Apparatus and system for gas compression and the method for compression of a gas

An apparatus and method of compressing a gas is provided. The system includes a gas storage tank and a liquid holding tank and a hollow cylinder. A piston is disposed in the hollow cylinder dividing the hollow cylinder into a first compartment and a second compartment. A gas collector tank is in fluid connection with the first compartment by an outline line. A radiator is provided in fluid connection with the second compartment and the liquid holding tank. The system also contains a pump. The apparatus system may also be coupled to a reactor system oxidizes a hydrocarbon-containing gas.

TECHNICAL HELD

In at least one aspect, the present invention is related to a gas compression system.

BACKGROUND

It is well known that gas and gas mixtures can be compressed in order to increase pressure and stored. Fluid controls many compression systems. Typically, synthetic oils are pumped into only one cylinder's side that result in movement of a piston and compress the gas. The high temperature and pressure required to result in movement of the piston require use of synthetic oil. Typically, the gas must be provided in isolation systems of pistons to avoid the mixture of oil and gas.

As we know, we can compress gas, or gas mixture, in order to increase the pressure, for example, between 10 and 600 bars, and put them inside vessels tanks and others, the application of one or more plants to determine the gas compression.

The compression plants are typical used for the alternative technic, one or more mono stage cylinders or one or more double-stage cylinders that included pistons compression.

This kind of compression plant is controlled by liquid fluid of control. Generally we refer to synthetic oils that are pumped into only one cylinder's side, that determinate the piston's movement about the alternation of compression and suction. The high temperature and pressure regarding the piston's movement needs the application of synthetic oil, in order to maintain during the proceed the operational characteristics unaltered.

The gas must be unaltered especially in those kinds of applications as the refilling of oxygen, hydrogen, methane, helium and the like into vessels or cylinders. For this reason it is necessary to provide an isolation system of pistons to avoid the mixture of synthetic oil and gas.

In order to maintain the plant's costs lower, usually is normal to use oil, even if this determine the mixture of the oil with gas, due to the strong components usury. This happened especially in several fields of gas compression, for example the utilization of oxygen, where is not allowed the presence of lubricating oils, that are dangerous in case of fire and or explosions.

Another inconvenient is about the high temperature that are created by the compression phase. This high temperature causes the degree increment about the compressed gas, that can create the thermodynamic variation of gas expansion, with several variations of compress conditions inside the vessel.

Obviously to reach the cooled gas with the correct pressure, is necessary to compress it in higher pressure and wait the balancing of this temperature inside the tank. In this situation, the vessel, in high temperature is not immediately manage manually.

Accordingly, there is a need for improvement of a low-cost gas compression system that avoids thermodynamic variation of expansion without contamination.

SUMMARY

In at least one aspect, the present invention relates generally to a novel system for the process of compressing and cooling gasses.

In another aspect, a gas compression system is provided. The system includes a gas storage tank and a liquid holding tank. In a refinement, the gas storage tank contains an uncompressed gas. A hollow cylinder is in fluid connection with both the gas storage tank and the liquid holding tank. A piston is disposed within the hollow cylinder. The piston divides the hollow cylinder into two compartments. A gas collector tank is in fluid connection with one compartment. A radiator is also provided and is in fluid connection with the second compartment of the hollow cylinder and the liquid holding tank. The system also includes a pump in fluid connection with the liquid holding tank and the second compartment of the hollow cylinder.

In another aspect, a gas compression system is provided. The system includes a first cylinder and a second cylinder connected by a sealing gasket. The system also includes two pistons. The first piston is slidably positioned in the first cylinder and defines a first compartment between the first piston and the sealing gasket. The second piston is slidably positioned in the second cylinder and defines a second compartment between the second piston and the sealing gasket. A stem connects the first piston and the second piston. A gas storage tank is in fluid connection with the first cylinder and first compartment. A liquid holding tank is in fluid connection with the second compartment and second cylinder. A pump is provided in fluid connection with the liquid holding tank. A gas collector tank is in fluid connection with the second compartment and first cylinder by an outlet line. A radiator is also included in fluid connection with the second cylinder, second compartment, and liquid holding tank.

In another aspect, a reaction assembly is provided. The reactor system includes a reactor system that oxidizes a hydrocarbon-containing gas. The assembly also includes a gas storage tank and a liquid holding tank. A hollow cylinder is in fluid connection with both the gas storage tank and the liquid holding tank. A piston is disposed within the hollow cylinder. The piston divides the hollow cylinder into two compartments. A gas collector tank is in fluid connection with one compartment. A radiator is also provided and is in fluid connection with the second compartment of the hollow cylinder and the liquid holding tank. The assembly also includes a pump in fluid connection with the liquid holding tank and second compartment of the hollow cylinder.

In another aspect, a gas compress plant can be constructed at a low budget by including simple components that compress gas with reduced contamination while avoiding the thermodynamic variation of gas during the compression phase.

In another aspect, the present invention provides the compression and cooling of simple and dangerous gases. In every single phase of this procedure, the gas must be separated from external agents as active agents, oils, dust and other organs that can change the chemical composition of gas.

In another aspect, the compression systems set forth herein provide the application for the refueling of technical pure gas, ultrapure, and inflammable as oxygen, hydrogen and all gas mixtures where there is a need for the chemical composition to be maintained unaltered.

In another aspect, a control circuit for the control fluid includes one or more coolers (e.g., fans with optional radiators) that pass the control fluid into compression organs (e.g. compression cylinders). The coolers can reduce the control fluid temperature.

In another aspect, a control fluid used to move a piston to compress a gas is water. Water is simpler and more economic than synthetic oils. Moreover, a single contact with a fluid control as water avoid risks of contaminations normally caused by oils.

Advantageously, the compression system set forth herein all refilling of vessels or tanks for high-pressure compression gas.

DETAILED DESCRIPTION

The term “substantially,” “generally,” or “about” may be used herein to describe disclosed or claimed embodiments. The term “substantially” may modify a value or relative characteristic disclosed or claimed in the present disclosure. In such instances, “substantially” may signify that the value or relative characteristic it modifies is within±0%, 0.1%, 0.5%, 1%, 2%, 3%, 4%, 5% or 10% of the value or relative characteristic.

The term “gas” as used herein mean a single gaseous component or a mixture of gaseous components.

It should also be appreciated that integer ranges explicitly include all intervening integers. For example, the integer range 1-10 explicitly includes 1, 2, 3, 4, 5, 6, 7, 8, 9, and 10. Similarly, the range 1 to 100 includes 1, 2, 3, 4 . . . 97, 98, 99, 100. Similarly, when any range is called for, intervening numbers that are increments of the difference between the upper limit and the lower limit divided by 10 can be taken as alternative upper or lower limits. For example, if the range is 1.1 to 2.1 the following numbers 1.2, 1.3, 1.4, 1.5, 1.6, 1.7, 1.8, 1.9, and 2.0 can be selected as lower or upper limits. In the specific examples set forth herein, concentrations, temperature, and reaction conditions (e.g. pressure, pH, etc.) can be practiced with plus or minus 50 percent of the values indicated rounded to three significant figures. In a refinement, concentrations, temperature, and reaction conditions (e.g., pressure, pH, etc.) can be practiced with plus or minus 30 percent of the values indicated rounded to three significant figures of the value provided in the examples. In another refinement, concentrations, temperature, and reaction conditions (e.g., pH, etc.) can be practiced with plus or minus 10 percent of the values indicated rounded to three significant figures of the value provided in the examples.

In the examples set forth herein, concentrations, temperature, and reaction conditions (e.g., pressure, pH, flow rates, etc.) can be practiced with plus or minus 50 percent of the values indicated rounded to or truncated to two significant figures of the value provided in the examples. In a refinement, concentrations, temperature, and reaction conditions (e.g., pressure, pH, flow rates, etc.) can be practiced with plus or minus 30 percent of the values indicated rounded to or truncated to two significant figures of the value provided in the examples. In another refinement, concentrations, temperature, and reaction conditions (e.g., pressure, pH, flow rates, etc.) can be practiced with plus or minus 10 percent of the values indicated rounded to or truncated to two significant figures of the value provided in the examples.

In at least one embodiment, a gas compression system is provided. The system includes a gas storage tank and a liquid holding tank. A hollow cylinder is in fluid connection with both the gas storage tank and the liquid holding tank. A piston is disposed within the hollow cylinder. The piston divides the hollow cylinder into a first compartment and second compartment. A gas collector tank is in fluid connection with first compartment by an outlet line. A radiator is also provided and is in fluid connection with the second compartment of the hollow cylinder and the liquid holding tank. The system also includes a pump in fluid connection with the liquid holding tank and second compartment of the hollow cylinder.

In a refinement, the system includes a temperature sensor operatively associated with the outlet line to measure the temperature of compressed gas. In another refinement the system includes a pressure sensor operatively associated with the outlet line to measure the pressure of compressed gas. The system may also have check valves disposed between the gas storage tank and first compartment and a second check valve disposed between the first compartment and the gas collector tank. The system may also have a first exchange valve disposed between the second compartment and the pump and a second exchange valve disposed between the second compartment and the radiator. In refinement the system may also have a limit switch associated with hollow cylinder. In further refinement the piston contains a magnet.

In another refinement, the system comprises a second hollow cylinder in fluid connection with the gas storage tank and liquid holding tank, a second piston slidably positioned in the second hollow cylinder dividing it into a third compartment and a fourth compartment. In this refinement, the third compartment is in fluid connection with the gas storage tank and the gas collector tank while the fourth compartment is in fluid connection with the pump and the radiator.

In at least another embodiment, a gas compression system is provided with two overlapping cylinders. The system comprises a first cylinder and second cylinder connected by a sealing gasket. The system also includes two pistons. The first piston is slidably positioned in the first cylinder and defines a first compartment between the first piston and the sealing gasket. The second piston is slidably positioned in the second cylinder and defines a second compartment between the second piston and the sealing gasket. A stem connects the first piston and the second piston. A gas storage tank is in fluid connection with the first cylinder and first compartment. A liquid holding tank is in fluid connection with the second compartment and second cylinder. A pump is provided in fluid connection with the liquid holding tank. A gas collector tank is in fluid connection with the second compartment and first cylinder by an outlet line. A radiator is also included in fluid connection with the second cylinder, second compartment, and liquid holding tank.

In a refinement, the system includes a temperature sensor operatively associated with the outlet line to measure the temperature of compressed gas. In another refinement the system includes a pressure sensor operatively associated with the outlet line to measure the pressure of compressed gas. The system may also have a first check valve disposed between the first compartment and the gas storage tank and a second check valve disposed between the first compartment and the gas collector tank. The system may also have a first exchange valve disposed between the second compartment and the pump and a second check valve disposed between the second compartment and the radiator. In refinement the system may also have two limit switches associated with the second cylinder laterally spaced from one another. In further refinement, the second piston contains a magnet.

In at least another embodiment, a reaction assembly is provided. The reactor system includes a reactor system that oxidizes a hydrocarbon-containing gas. The assembly also includes a gas storage tank and a liquid holding tank. A hollow cylinder is in fluid connection with both the gas storage tank and the liquid holding tank. A piston is disposed within the hollow cylinder. The piston divides the hollow cylinder into two compartments. A gas collector tank is in fluid connection with one compartment. A radiator is also provided and is in fluid connection with the second compartment of the hollow cylinder and the liquid holding tank. The assembly also includes a pump in fluid connection with the liquid holding tank and second compartment of the hollow cylinder. In refinement, the system includes a temperature sensor operatively associated with the outlet line to measure the temperature of compressed gas.

In another refinement, the system includes a pressure sensor operatively associated with the outlet line to measure the pressure of compressed gas. The system may also have check valves disposed between the gas storage tank and first compartment and a second check valve disposed between the first compartment and the gas collector tank. The system may also have a first exchange valve disposed between the second compartment and the pump and a second exchange valve disposed between the second compartment and the radiator. In refinement the system may also have a limit switch associated with hollow cylinder. In further refinement the piston contains a magnet.

In another refinement, the system comprises a second hollow cylinder in fluid connection with the gas storage tank and liquid holding tank, a second piston slidably positioned in the second hollow cylinder dividing it into a third compartment and a fourth compartment. In this refinement, the third compartment is in fluid connection with the gas storage tank and the gas collector tank while the fourth compartment is in fluid connection with the pump and the radiator.

With reference to the attached figures, an installation according to the present invention is used for the compression of a gas, in this case, an oxygenate (e.g., methanol, formaldehyde, oxygen, alcohols, and the like) or other gases for fil ling cylinders for all types of use. As said, it is not excluded that the plant can be equally applied for the compression of other gases, or gas mixtures, such as methane or others. It should be appreciated that components of any subsystem described in a figure can be integrated into the systems of the other figure.

With reference toFIG.1, gas compression system10includes gas inlet tank12and gas outlet tank14. In a refinement, gas inlet tank12and gas outlet tank14is connected to one side of cylinder26. Gas is introduced into cylinder26from gas inlet tank12. Gas outlet tank14is of an adequate size to accumulate a predetermined minimum volume of compressed gas. Gas compression system10also includes a first inlet line20through which gas to be compressed flow from the inlet tank12and a second outlet line22which injects the compressed gas into gas outlet tank14. The first line20is connected at column inlet line24to at least one compression cylinder26through check valves28and30.

Moreover, downstream of the check valves into the outlet direction of the gas, a pressure transducer34is operatively associated, arranged to detect the pressure at which the compressed gas is located inside the outlet line22. Outlet line22includes a safety valve36to guarantee the gas pressures under control.

The control subassembly40includes an electric pump42, or any fluid pumping device, a liquid holding tank44which optionally includes a level sensor46. In a refinement, control subassembly40is a fluid (e.g., water) compression circuit. Control subassembly40also includes a heat exchanger50(e.g., a cooling fan) and a plurality of controllable valve (e.g., high-pressure valves52,54,56) suitable for distributing the control fluid alternately in compression cylinder26. The heat exchanger50is located at a position proximate to column26such that the control fluid (e.g., water) is maintained (e.g., cooled) to be at a predetermined controlled operating temperature. As set forth below, these components allow control fluid pumped by the electric pump42is alternatively pumped into cylinder26and liquid holding tanking44via coordinated operation of check valves28and30which are adapted to permit alternatively the gas inlet and of the compression cylinder26due to the orientation of their directionality.

In a refinement, a fluid temperature sensor is present in one or more of control fluid lines60,62, and/or64to keep the control fluid temperature under control. Control fluid line60connects liquid holding tank44to pump42. In a further refinement, control fluid line62connect radiator66to liquid holding tanking tank44. In another refinement, the control fluid flows through or proximate to radiator66.

Piston70contacts perimetrically the inner circular surface of the cylinder26through the respective guide and gaskets selings, so as to make the two compartments substantially sealed between them, to divide hermetically the control fluid (water) and the fluid to be compressed (gas or gas mixture). In a refinement, piston70is slidably arranged to define two separate column spaces72,74with variable volumes. The gas is introduced into and compressed in column space72. The control fluid76in introduced into column space74in order to compress the gas.

The procedure for compressing a gas with gas compression system10follows. With reference toFIG.1, the gas is introduced through the inlet line20of the compression circuit inside the cylinder26. In particular, the gas is introduced into the cylinder26at a pressure of about 4 bar or 200 bar. At the same time, the electric pump42pumps the control fluid (e.g., water) inside the high-pressure fluid circuit, and the valve52open, directs the pumped control fluid towards the cylinder26. The control fluid can be any liquids that do not compromise the chemical composition of gas being compressed. In a refinement, the control fluid is water. The electric pump42works with greater pressure on the control fluid and is sufficient to overcome the force caused by the gas during the compression phase. This condition causes the compression by the piston70to be raised by compressing the gas present inside it. This compression causes an exit of the gas from the cylinder26through the check valve30, with consequent of the gas compression circuit, and compressed is introduced into the gas outlet tank14. Arrows a1-a9show the directions that the control fluid flows.

When the piston70reaches of the limit switch, the magnetic sensor80detects the magnet present inside the piston70, the magnet is isolated and is not in contact with any of the fluids present in the cylinders. This condition detected by the sensor80causes the activation (i.e., opening) of valves54and56and at the same time the closing of the valve52. Therefore, control fluid is directed to liquid holding tanking44by the force of the gas which pushes the piston70downwards. When the piston70is detected by the magnetic sensor84, valves54and56close followed by the opening of valve52. This allows the control fluid to flow into column26again thereby compressing the gas.

The alternate control fluid pumping and gas compression exchange is repeated until the pressure sensor34of the gas compression subassembly signals that the desired gas compression pressure has been reached inside gas outlet tank14.

In another variation, compression system10includes one or a plurality of compression cylinders26alternately coordinated with each other to compress the gases. Characteristically, each of a a plurality of compression cylinders26are of the design set forth above. In particular, each cylinder is connected to a gas inlet line, gas outlet line, column inlet line and a control subassembly as set forth above.

FIG.2provides a schematic illustration for a gas compression system with two independent compression organs. The term “organ” as used herein mean device. Gas compression system100, includes gas inlet tank115. Gas inlet tank115is in fluid communication through inlet line117to the two compression organs113A,113B. The gas moves from inlet line117through inlet check valves120A,120B to the respective compression organs113A,113B. The gas flows from compression organs113A,113B through check valves121A,121B. A pressure sensor122operatively associated with outlet line119to detect the pressure of the compressed gas located inside outlet line119. A temperature sensor118operatively associated with outlet line119detects the temperature of the compressed gas located inside outlet line119. Downstream of the pressure sensor122and temperature sensor118is a gas outlet tank116. The compressed gas moves from the two compression organs113A,113B via outlet line119to the gas outlet tank116.

Each compression organ (113A,113B) includes a hollow cylinders133A,133B, inside which a piston136A,136B is disposed transversely. The piston136A is slidably positioned inside the cylinder133A along a longitudinal direction so as to define two separate compartments (139A,135A with variable volume inside each cylinder133A. The piston136B is slidably positioned inside the cylinder133B along a longitudinal direction so as to define two separate compartments (139B,135B with variable volume inside each cylinder133B. The pistons136A,136B contact the inner circular surface of the cylinder133A,133B through respective sealing gaskets so the separate compartments are substantially isolated from one another.

The system ofFIG.2also includes a control circuit112with a water pump123, storage tank125, radiator126, intake line127, and discharge line129. The water pump123may be an electric pump or any suitable alternative. A control fluid circulates inside the control circuit112. The control fluid in this instance is water. The intake line127connects the water pump123with the two compression organs113A,113B. The intake line127branches into two sections and transfers water to the two compression organs113A,113B by two respective exchange valves130A,130B. A pressure switch131is operatively associated with intake line127and located between water pump123and exchange valves130A,130B. Pressure switch131detects the pressure at which the water is pumped inside the intake line127. The discharge line129is connected to the two compression organs113A,113B by corresponding exhaust valves132A,132B. A radiator126is located downstream of the exhaust valves132A,132B. A water temperature sensor124operatively associated with the discharge line129detects the temperature of the water in discharge line129. The discharge line129connects the radiator126to a storage tank125.

Inlet line117and outlet line119are in fluid connection with compartments139A and139B. Intake line127and discharge line129are in fluid connection with compartments135A and135B. In this way, compression circuit111and control circuit112are associated with opposite sides of each compression organ113A,113B.

The system exemplified inFIG.2operates as follows. Gas from gas inlet tank115is introduced through the inlet line117of the compression circuit111. The gas moves through inlet line117and through inlet check valves120A,120B into compartment139A of cylinder133A and compartment139B of cylinder133B. The gas is introduced into compartments139A and139B at a pressure of approximately 4 bar. Sequentially or simultaneously with the flow of the gas, water is pumped from the storage tank125by the water pump123. The water travels through intake line27of the control circuit12through exchange valves130A into compartment135A of cylinder133A. The water pump123operates with a pressure such that it is sufficient to overcome the force caused by the gas during compression of the gas. This results in the piston136A of cylinder133A raising the piston136A and compressing the gas located in compartment139A. The compression causes the gas to exist from cylinders133A through check valves121A. The compressed gas from compartment135A travels through outlet line19of the compression circuit111to gas outlet tank116.

When the piston136A in cylinder133A reaches the limit switch, a magnetic sensor134A detects a magnet present within piston136. The magnet is isolated and is not in contact with any of the fluids present in the cylinder. The detection by magnetic sensor134A activates exchange valve130B and exhaust valve132A and closes exchange valve130A. Water present inside compartment135A is evacuated due to the force of the gas which pushes the piston downwards. Water from compartment135A is discharged and conveyed by discharge line129towards the radiator126where it is cooled to a predetermined temperature. The cooled water is temporarily stored in storage tank125before being pumped by water pump123back into intake line127. The water is then directed towards cylinder133B. Using similar methods as described with respect to cylinder133A, the water pumped into compartment135B of cylinder133B compresses the gas introduced into compartment139B. The compressed gas from compartment135B travels through outlet line119of the compression circuit111to gas outlet tank116.

The alternation of water pumping and gas compression exchange is repeated until pressure sensor122of the compression circuit111detects that the desired gas compression pressure has been reached inside gas outlet tank116. The system ofFIG.2may also operate with a single compression organ wherein the flow of water and gas into their respective compartments is sequential.

FIG.3provides another schematic illustration for a gas compression system with two overlapping compression organs. In this example, gas compression system200includes a compression circuit211, a control circuit212, and a single compression organ213formed by two overlapping cylinders233A,233B. The compression circuit has a gas inlet tank215at one end and a gas outlet tank216at the other end. The gas inlet tank215is in fluid connection with inlet line217. Inlet line217is in fluid connection with the compression organ via check valves220A and220B. A minimum pressure sensor222.1is operatively connected to inlet line217to prevent it from being pressure-free resulting in a vacuum. Check valves221A,221B are in fluid connection with the compression organ213. An outlet line219is in fluid connection and downstream of check valves221A,221B. A pressure sensor222and a temperature sensor218are operatively associated and arranged to detect the pressure and temperature at which the compressed gas is located within the outlet line219.

The compression organ213includes two hollow cylinders233A,233B inside which two pistons236A,236B are transversely connected by a stem237. Both pistons236A,236B are slidable along a longitudinal direction and define compartments235A,235B. Piston236A contacts the inner circular surface of cylinder233A, while piston236B contacts the inner circular surface of cylinder233B. The cylinders233A,233B are separated by an intermediate flange238and sealing gasket240in which the stem237slides. Compartments235C,235D are formed between the sealing gasket and pistons236A and236B, respectively.

The system ofFIG.3also includes a control circuit212. The control circuit212includes a pump223, an accumulation tank225, a cooling radiator226, a supply line227and a discharge line229. The cooling radiator226may be an electro-ventilated cooler or any other reasonable substitute known to those skilled in the art. A control fluid circulates within the control circuit. The control fluid is preferably water. The pump223contains a pressure sensor231operatively associated and arranged to detect the pressure at which the fluid pumped inside the supply line227.

The supply line227is in fluid connection with the pump223and the compression organ213. The supply line227is divided into two branches by two exchange valves230A,230B, which are arranged between the pump223and cylinder233B. The discharge line229is divided into two branches each connected to an outlet of the cylinder233B by two related outlet valves232A,232B. The discharge line229also fluidly connects the cooling radiator226to the accumulation tank225. The inlet line217and outlet line219of the compression circuit211are in fluid connection with compartment235A of compression organ213. Branches of the supply line227and discharge line229of the control circuit212are in fluid connection with235B of compression organ213.

The system exemplified inFIG.3operates as follows. Gas flows from gas inlet tank215through the inlet line217of the compression circuit211to compartment235C of the cylinder233A via check valve220B. The gas is introduced at a pressure of approximately 2 bar. Simultaneously or sequentially, the pump223pumps fluid from accumulation tank225through supply line227of the control circuit towards the flange238into compartment235D. Valves230A,232B are open. The pump223operates at a higher pressure on the fluid and is sufficient to overcome the force caused by the gas during the compression phase. This causes the pistons236A,236B to be lowered, compressing the gas in compartment235C and causing it to exit through the check valve221B. The compressed cases travel through the outlet line219of the compression circuit into the gas outlet tank216.

When the piston236B reaches the limit switch, the magnetic sensor B33detects the magnet present in the piston236B. The magnet is isolated and is not in contact with any of the fluids present in the cylinder233B. Upon detection by the sensor B33, activation of the valves230A and232B occurs while at the same time the closing of valves232A and230B. The fluid is directed towards the cylinder233A. The water inside compartment235D is evacuated due to force of the water which pushes the piston upwards. The water drained travels by the discharge line229towards the cooling radiator226where its temperature is reduced. The cooled fluid is temporarily deposited in the accumulation tank225before being drawn by the pump223and re-pumped into the supply line227.

The water is then pumped into compartment235B of cylinder233B. Gas flows through check valve220A into compartment235A of cylinder233A. The pressure of the water flowing into compartment235B causes the pistons236A,236B to be raised which compresses the gas in compartment235A. The compressed gas exits the compartment235A through valve221A through the outlet line219of the compression circuit into the gas outlet tank216.

Both the system ofFIG.2and the system ofFIG.3may be coupled to reactor as set forth in U.S. Pat. Nos. 7,910,787 and 10,099,199, the entirety of which are incorporated herein. The system ofFIG.4illustrates the gas compression system ofFIG.2coupled to a reactor system400. Reactor system400facilitates gas-phase oxidation of a hydrocarbon-containing gas.

FIG.5illustrates an exemplary schematic for the reactor system400coupled to a gas compression system300.FIG.5details the inputs and outputs of the reactor. The reactor440has a reaction zone which is provided with a device for introducing a heated hydrocarbon-containing gas stream and a device for introducing an oxygen-containing compressed gas. The oxygen-containing compressed gas preferably has greater than 80% oxygen content to reduce the accumulation of inert gases by the recycling process.

The reactor440further has a regulation zone408provided with an optional device for introducing a cold hydrocarbon-containing gas stream for reducing the temperature of the reaction during operation of the apparatus. In addition, the reactor440is provided with thermal pockets for control and regulation of temperatures in corresponding zones, provided for example with thermocouples.

The apparatus has a device for cooling the reaction mixture before separation. Additionally, the partial condenser422incorporations a gas-liquid heat exchanger to further reduce the temperature of the products. The condenser422separates water and alcohols from a hydrocarbon-carbon dioxide mixture. The partial condenser422is preferably isobaric, as opposed to isothermal to avoid pressure losses. The product stream enters, and liquid stream and gaseous stream exist the condenser422.

Block439represents equipment that is configured to separate contaminants and products from a hydrocarbon-containing recycle gas component. In this regard, block439is configured to remove carbon dioxide from the reduced product stream. The equipment439can take the form of a purge valve, absorber, membrane separator, or an absorber. It is envisioned the equipment439can be used to regulate the percentage of other non-reactive components such as nitrogen as with, for example, a purge valve.

In the event the system is configured to recover formaldehyde, the gaseous reduced product stream leaves the condenser422and is passed to the scrubber434. Other potential methods that can be utilized use materials such as various amines known to remove CO2and formaldehyde. To fulfill the minimum absorption requirements, modification of the flow rate of methanol or operating temperature of the scrubber column can be used. If it is desirable to operate at extremely low absorbent flow rates, then a lower temperature can be utilized, for example 0° C. If it is desirable to operate at ambient temperatures or temperatures achievable via cooling water, then a high flow rate can be utilized, for example, ten times that of the flow rate for 0° C. In either scenario, the pregnant methanol absorbent stream514is completely regenerated by the formaldehyde distillation column438. Optionally, the stream514from the scrubber434can be passed through the condenser422to provide cooling of the product stream and preheating of the methanol recycle to improve the energy efficiency of the formaldehyde distillation column438.

The reactor440is connected with a compressor424and heater426for the supply of compressed and heated oxygen-containing gas. The raw hydrocarbon-containing gas is mixed with cleaned hydrocarbon gas from the scrubber434and is heated using a heater436. In the event the raw hydrocarbons have a high CO2content, the raw hydrocarbons can be mixed with the reduced product hydrocarbon stream from the condenser422prior to the entry of the scrubber434for removal of contaminant gases prior to entering the reactor.

The apparatus further has a unit for rectification of methanol which includes a flash drum432, rectification column428, and a vessel430from which methanol is supplied to storage or further processing. This rectification column428is used to separate methanol (light-key component) from ethanol (heavy-key component) and water (non-key component). As before, it is desirable for a portion of the heavy key to enter the distillate stream (as dictated by commercial specification for formalin). For methanol rectification, 99% or higher purity is typical and 99.999% is achievable with multiple columns. Stream4enters the column and the distillate, stream5, and bottoms, stream8, exit the column in liquid phase. Stream8has some amount of ethanol (and perhaps methanol, if ultra-pure methanol was produced) and will be used as the basis of the aqueous makeup of the commercial formalin stream (stream11). In this manner, some of the ethanol is recovered before the remainder is discarded in the liquid waste stream.

Disposed between the column428and the condenser422is a hash drum432for removal of CO2and formaldehyde from the liquid product stream. The purpose of the flash drum432is to drop the pressure to an appropriate level before entry into the methanol rectification column428and to substantially remove any dissolved gases, typically CO2and formaldehyde, from the liquid product stream.

In operation, the raw hydrocarbon-containing gas stream with a methane content for example up to 98% and the reduced hydrocarbon product stream are supplied from an installation for preparation of gas or any other source to the heater436, in which it is heated to temperature 430-470° C. The heated hydrocarbon-containing gas is then supplied into the reaction zone of the reactor440. Compressed air with pressure, for example, of 7-8 MPa and with a ratio 80% to 100% and, preferably, 90% to 95% oxygen is supplied by the compressor424also into the reaction zone of the reactor440. Oxidation reaction takes place in the reaction zone of the reactor440. Between 2% and 3% 0 2 of the total volume of the reactants are reacted with the heated hydrocarbon-containing gas stream as previously described. To limit the amount of N2within the system, for example to less than 30%-40%, or reduce the requisite size of the purge stream to achieve the same, the stream is preferably substantially pure, thus limiting the amount of N2entering the system.

An optional second stream of cold or in other words a lower temperature coolant than the gases in the reactor is supplied through the introducing device into the regulation zone of the reactor440. This stream is regulated by the regulating device420, which can be formed as a known gas supply regulating device, regulating valve or the like. This cold stream can be, for example, composed of a raw hydrocarbon stream, a recycled stream, or a portion or combination of the two. The regulator is configured to adjust the volume or pressure of cold hydrocarbon-containing gas based on system parameters such as, but not limited to, pressure, temperature or reaction product percentages downstream in the system.

The reaction mixture is supplied into the heat exchanger414for transfer of heat to the reactor input stream from the reaction mixture exiting the reactor, and after further cooling is supplied within partial condenser422. Separation of the mixture into high and low volatility components, (dry gas and raw liquid, respectively) is performed in the partial condenser422which may absorb at least some of the formaldehyde into the raw liquid stream as desired. The dry gas is forwarded to a scrubber434, while the raw liquids from the condenser422are supplied to the flash drum432.

The scrubber434functions to remove the CO2and formaldehyde from the dry gas stream. In this regard, the scrubber434uses both H2O and methanol at between 7-8 MPa pressure and between about 0° C. and about 50° C. to absorb CO2and formaldehyde. Once the CO2and formaldehyde are removed, the reduced stream of hydrocarbon gas is recycled by mixing the reduced stream with the raw hydrocarbon-containing gas stream either before or within the reactor, as desired. The raw hydrocarbon and reduced streams, individually or in combination, are then inputted into the reaction chamber.

The rectification column is used to separate carbon dioxide (non-key component) and formaldehyde (light-key component) from methanol (heavy-key component) and water (non-key component). The pregnant methanol stream514, enters the rectification column and is separated into a formaldehyde distillate, stream516, and a bottoms stream, stream515. Some amount of methanol in the distillate stream is desirable since methanol is used as a stabilizer for the production of commercial-grade formalin (6-15% alcohol stabilizer, 37% formaldehyde, and the balance being water). By allowing a portion of the heavy key into the distillate stream the separation is more easily achieved; furthermore, process losses typically experienced during absorbent regeneration are subsequently nullified as methanol within the distillate is used for formalin production. Stream515is supplemented by stream31so as to replace any methanol which was transferred to the distillate stream, stream516. Combining stream31and stream515results in stream17, which then returns to the scrubber34as regenerated methanol absorbent. Meanwhile, the formaldehyde distillate, stream516, combines with the vapors from so flash drum432, stream7, to form a mixture of formaldehyde, methanol, and carbon dioxide.

The formaldehyde, water, methanol, and CO2removed by scrubber434are passed to formaldehyde rectification column438. Column438removes formaldehyde and CO2from the methanol-water stream. Small amounts of methanol are combined with produced methanol and are inputted into the scrubber434to remove additional amounts of CO2and formaldehyde from the reduced hydrocarbon stream. Free or non-aqueous formaldehyde is allowed to remain in the gas phase by operation of the isobaric condenser422. The liquid methanol product stream, or raw liquids, would then comprise methanol, ethanol, and water by allowing formaldehyde to remain in the gaseous stream. In this case, the liquid stream exiting the isobaric condenser422can bypass the formaldehyde rectification portion of the process and enter the methanol rectification column after having optionally passed through the flash drum432.

FIG.6illustrates a schematic where the number of compression chambers is increased within a single system.

The above-described embodiments of the invention are presented for purposes of illustration and not of limitation. While these embodiments of the invention have been described with reference to numerous specific details, one of ordinary skill in the art will recognize that the invention can be embodied in other specific forms without departing from the spirit of the invention. Thus, one of ordinary skill in the art would understand that the invention is not to be limited by the foregoing illustrative details, but rather is to be defined by the appended claims.