US 12,252,461 B2
Autonomous modular flare gas conversion systems and methods
Paul E Yelvington, Rockledge, FL (US); Bunmi Tolu Adekore, Medford, MA (US); Joshua B. Browne, New York, NY (US); John Anthony Dean, Scotia, NY (US); and Andrew Randolph, Salisbury, NC (US)
Assigned to M2X Energy Inc., Rockledge, FL (US)
Filed by M2X Energy Inc., Rockledge, FL (US)
Filed on May 15, 2023, as Appl. No. 18/197,308.
Application 18/197,308 is a continuation of application No. 17/746,942, filed on May 17, 2022, granted, now 11,649,201.
Claims priority of provisional application 63/213,129, filed on Jun. 21, 2021.
Claims priority of provisional application 63/197,898, filed on Jun. 7, 2021.
Claims priority of provisional application 63/189,756, filed on May 18, 2021.
Prior Publication US 2024/0124377 A1, Apr. 18, 2024
This patent is subject to a terminal disclaimer.
Int. Cl. C07C 29/151 (2006.01); B01D 53/02 (2006.01); B01D 53/22 (2006.01); B01J 12/00 (2006.01); B01J 19/00 (2006.01); C01B 3/02 (2006.01); C01B 3/36 (2006.01); C01C 1/04 (2006.01); C07C 1/04 (2006.01); C10L 3/08 (2006.01); F02C 3/30 (2006.01)
CPC C07C 29/1518 (2013.01) [B01D 53/02 (2013.01); B01D 53/229 (2013.01); B01J 12/005 (2013.01); B01J 19/004 (2013.01); C01B 3/025 (2013.01); C01B 3/36 (2013.01); C01B 3/366 (2013.01); C01C 1/0488 (2013.01); C07C 1/0485 (2013.01); C10L 3/08 (2013.01); F02C 3/30 (2013.01); B01D 2256/16 (2013.01); B01J 2219/00182 (2013.01); B01J 2219/00186 (2013.01); C01B 2203/025 (2013.01); C01B 2203/061 (2013.01); C01B 2203/062 (2013.01); C01B 2203/068 (2013.01); C01B 2203/1241 (2013.01); C01B 2203/1614 (2013.01); C01B 2203/1628 (2013.01); C01B 2203/82 (2013.01); C10L 2200/0461 (2013.01); C10L 2290/02 (2013.01); C10L 2290/145 (2013.01); F05D 2220/75 (2013.01)] 24 Claims
OG exemplary drawing
 
1. A continuous method of converting a flare gas to methanol, the method comprises:
a. receiving a flare gas flow from a source, wherein:
i. the flare gas flow has a rate of about 50,000 scfd to about 30,000,000 scfd;
ii. the flare gas flow has a composition, wherein the composition varies over time;
b. compressing the flare gas flow to provide a compressed flare gas flow, wherein the compressed flare gas flow has a pressure of about 8 bar to about 60 bar;
c. mixing the compressed flare gas flow with air to provide a rich fuel/air mixture;
d. partially oxidizing the rich fuel/air mixture at a temperature of from about 700° C. to about 1,200° C. in a reformer to provide a reprocessed gas flow; wherein the reprocessed gas flow comprises a syngas having a syngas composition;
e. passing the reprocessed gas flow through a deoxygenation reactor, whereby oxygen is removed from the reprocessed gas flow, thereby providing a deoxygenated reprocessed gas flow;
f. removing water from the deoxygenated reprocessed gas flow to thereby provided a syngas flow;
g. controlling the pressure and the temperature of the syngas flow to provide a predetermined synthesis temperature and synthesis pressure of the syngas flow;
h. flowing the syngas flow at the predetermined synthesis temperature and synthesis pressure into a synthesis unit;
i. converting the syngas flow in the synthesis unit to thereby provide a first product stream comprising methanol;
j. removing a material from the first product stream, the material comprising hydrogen; to thereby provide a second product stream; wherein the second product stream comprises at least about 80% methanol, and is thereby at least about 80% pure; and,
k. wherein the predetermined synthesis pressure is from about 30 bar to about 100 bar.