PISTONLESS APPARATUS AND SYSTEM FOR GAS COMPRESSION AND THE METHOD FOR COMPRESSION OF A GAS

Abstract

A gas compression system includes a first hollow cylinder with a top and bottom, a gas source for relatively uncompressed gas entering through the top, and a gas collector tank connected by an outlet line. The gas compression system includes a liquid holding tank with liquid connected to the first cylinder bottom and a pump linking the liquid holding tank to the first cylinder bottom. An actuation system controls the liquid and gas input/output, and a controller manages the pump to move liquid at a higher pressure than the relatively uncompressed gas. This vertical movement of liquid compresses the gas, and the controller releases the compressed gas into the collector tank when it exceeds a predetermined pressure. A gas compression system with two hollow cylinders is also provided.

Claims

1. A gas compression system comprising: a first hollow cylinder having a first cylinder bottom and a first cylinder top; a gas source in fluid communication with the first cylinder top, the gas source providing a relatively uncompressed gas that enters the first hollow cylinder through the first cylinder top; a gas collector tank in fluid connection with the first cylinder top by an outlet line; a liquid holding tank that includes liquid in fluid communication with the first cylinder bottom; a pump in fluid connection with the liquid holding tank and the first cylinder bottom; an actuation system configured to control input of liquid and relatively uncompressed gas into the first hollow cylinder and output of compressed gas and liquid from the first hollow cylinder; and a controller configured to control the actuation system, wherein the controller enables the pump to move liquid from the liquid holding tank into the first hollow cylinder through the first cylinder bottom at a higher pressure than the relatively uncompressed gas, thereby causing a liquid surface to move in a vertical direction within the first hollow cylinder, compressing the relatively uncompressed gas into compressed gas, and wherein the controller enables release of the compressed gas into the gas collector tank when its pressure is greater than a first predetermined high gas pressure.

2. The gas compression system of claim 1, wherein the first predetermined high gas pressure is greater than 1000 psi.

3. The gas compression system of claim 1 further comprising a pressure sensor operatively associated with the outlet line to measure pressure of a compressed gas.

4. The gas compression system of claim 1 further comprising a temperature sensor operatively associated with the outlet line to measure temperature of a compressed gas.

5. The gas compression system of claim 1 operated by a method of filling the first hollow cylinder with the relatively uncompressed gas, filling the first hollow cylinder with liquid to compress the relatively uncompressed gas, and then collecting the compressed gas.

6. The gas compression system of claim 1, wherein the actuation system includes a first gas inlet actuated valve and a first gas outlet actuated valve in electrical communication with the controller, the first gas inlet actuated valve being disposed between the first hollow cylinder and the gas source to control entry of the relatively uncompressed gas into the first hollow cylinder and the first gas outlet actuated valve being disposed between the first hollow cylinder and the gas collector tank to control exiting of the compressed gas from the first hollow cylinder.

7. The gas compression system of claim 6, wherein the actuation system further includes a first liquid inlet actuated valve and a first liquid outlet actuated valve in electrical communication with the controller, the first liquid inlet actuated valve being disposed between the first hollow cylinder and the liquid holding tank to control entry of the liquid into the first hollow cylinder and the first liquid outlet actuated valve being disposed between the first hollow cylinder and the liquid holding tank to control exiting of the liquid from the first hollow cylinder.

8. The gas compression system of claim 7 operated by a method comprising: a) closing both the first liquid inlet actuated valve and the first liquid outlet actuated valve; and b) opening a gas inlet actuated valve and filling the first hollow cylinder to a predetermined low pressure; c) closing the gas inlet actuated valve when the pressure is equal to or greater than the predetermined low pressure; d) opening the first liquid inlet actuated valve to introduce liquid into the first hollow cylinder; e) closing the first liquid inlet actuated valve when the first predetermined high gas pressure is achieved; f) opening the first gas outlet actuated valve to allow gas to flow to a gas collector tank; g) closing the first gas outlet actuated valve when the pressure in the first hollow cylinder falls below a predetermined cylinder pressure; h) opening the first liquid outlet actuated valve, followed by opening the gas inlet actuated valve; i) closing the gas inlet actuated valve when the pressure is equal to or greater than the predetermined low pressure; and j) cycling back to step d).

9. The gas compression system of claim 7 further comprising a first gas inlet pressure sensor for measuring the pressure of gas entering the first hollow cylinder and a first gas outlet pressure sensor for measuring the pressure of gas exiting the first hollow cylinder, the first gas inlet pressure sensor being disposed between the first hollow cylinder and the first gas inlet actuated valve and the first gas outlet pressure sensor being disposed between the first hollow cylinder and the first gas outlet actuated valve 48.

10. The gas compression system of claim 9 further comprising a first liquid inlet pressure sensor for measuring the pressure of liquid entering the first hollow cylinder and a first liquid outlet pressure sensor for measuring the pressure of liquid exiting the first hollow cylinder, the first liquid inlet pressure sensor being disposed between the first hollow cylinder and the first liquid inlet actuated valve and the first liquid outlet pressure sensor.

11. The gas compression system of claim 1, further comprising a radiator in fluid connection with the first cylinder bottom and the liquid holding tank, wherein the radiator cools liquid before it enters the liquid holding tank.

12. The gas compression system of claim 1 further comprising: a second hollow cylinder in fluid connection with the gas source, the liquid holding tank, and the pump, the second hollow cylinder having a second cylinder bottom and a second cylinder top, wherein the controller is further configured to enables the pump to move liquid from the liquid holding tank into the second hollow cylinder at a higher pressure than the relatively uncompressed gas, thereby causing a liquid surface to move in a vertical direction within the second hollow cylinder, compressing the relatively uncompressed gas into compressed gas, and wherein the controller enables release of the compressed gas into the gas collector tank when its pressure is greater than the first predetermined high gas pressure in the second hollow cylinder.

13. A gas compression system comprising: a first hollow cylinder having a first cylinder bottom and a first cylinder top; a second hollow cylinder having a second cylinder bottom and a second cylinder top; a gas source including a relatively uncompressed gas in fluid communication with the first cylinder top and the second cylinder top such that relatively uncompressed gas enters the first hollow cylinder through the first cylinder top and/or the second hollow cylinder through the second cylinder top; a gas collector tank in fluid connection with the first cylinder top and the second cylinder top by an outlet line; a liquid holding tank that includes liquid in fluid communication with the first cylinder bottom and the second cylinder bottom; and a pump in fluid connection with the liquid holding tank, the first cylinder bottom, and the second cylinder bottom; an actuation system configured to control input of liquid and relatively uncompressed gas into the first hollow cylinder and second hollow cylinder and output of compressed gas and liquid from the first hollow cylinder and the second hollow cylinder; and a controller configured to control the actuation system, wherein the controller enables the pump to move liquid from the liquid holding tank into the first hollow cylinder and/or the second hollow cylinder at a higher pressure than the relatively uncompressed gas, thereby causing a liquid surface to move in a vertical direction within the first hollow cylinder and/or the second hollow cylinder, compressing the relatively uncompressed gas into compressed gas, and wherein the controller enables release of the compressed gas into the gas collector tank when its pressure is greater than a first predetermined high gas pressure in either the first hollow cylinder or the second hollow cylinder.

14. The gas compression system of claim 13, wherein the first predetermined high gas pressure is greater than 1000 psi.

15. The gas compression system of claim 13 further comprising a pressure sensor operatively associated with the outlet line to measure pressure of a compressed gas.

16. The gas compression system of claim 13 further comprising a temperature sensor operatively associated with the outlet line to measure temperature of a compressed gas.

17. The gas compression system of claim 13 operated by a method of filling the first hollow cylinder with the relatively uncompressed gas, filling the first hollow cylinder with liquid to compress the relatively uncompressed gas, and then collecting the compressed gas.

18. The gas compression system of claim 13, wherein the actuation system includes a first gas inlet actuated valve, a first gas outlet actuated valve, a second gas inlet actuated valve, and a second gas outlet actuated valve in electrical communication with the controller, the first gas inlet actuated valve being disposed between the first hollow cylinder and the gas source to control entry of the relatively uncompressed gas into the first hollow cylinder, the first gas outlet actuated valve being disposed between the first hollow cylinder and the gas collector tank to control exiting of the compressed gas from the first hollow cylinder, the second gas inlet actuated valve being disposed between the second hollow cylinder and the gas source to control entry of the relatively uncompressed gas into the second hollow cylinder, and the second gas outlet actuated valve being disposed between the second hollow cylinder and the gas collector tank to control exiting of the compressed gas from the second hollow cylinder.

19. The gas compression system of claim 18, wherein the actuation system further includes a first liquid inlet actuated valve and a first liquid outlet actuated valve, a second liquid inlet actuated valve, and a second liquid outlet actuated valve all in electrical communication with the controller, the first liquid inlet actuated valve being disposed between the first hollow cylinder and the liquid holding tank to control entry of the liquid into the first hollow cylinder and the first liquid outlet actuated valve being disposed between the first hollow cylinder and the liquid holding tank to control exiting of the liquid from the first hollow cylinder, the second liquid inlet actuated valve being disposed between the second hollow cylinder and the liquid holding tank to control entry of the liquid into the second hollow cylinder and the second liquid outlet actuated valve being disposed between the second hollow cylinder and the liquid holding tank to control exiting of the liquid from the second hollow cylinder.

20. The gas compression system of claim 19 further comprising a first gas inlet pressure sensor for measuring the pressure of gas entering the first hollow cylinder and a first gas outlet pressure sensor for measuring the pressure of gas exiting the first hollow cylinder, the first gas inlet pressure sensor being disposed between the first hollow cylinder and the first gas inlet actuated valve and the first gas outlet pressure sensor being disposed between the first hollow cylinder and the first gas outlet actuated valve.

21. The gas compression system of claim 20 further comprising a first liquid inlet pressure sensor for measuring the pressure of liquid entering the first hollow cylinder and a first liquid outlet pressure sensor for measuring the pressure of liquid exiting the first hollow cylinder, the first liquid inlet pressure sensor being disposed between the first hollow cylinder and the first liquid inlet actuated valve and the first liquid outlet pressure sensor.

22. The gas compression system of claim 19 further comprising a second gas inlet pressure sensor for measuring the pressure of gas entering the second hollow cylinder and a second gas outlet pressure sensor for measuring the pressure of gas exiting the second hollow cylinder, the second gas inlet pressure sensor being disposed between the second hollow cylinder and the second gas inlet actuated valve and the second gas outlet pressure sensor being disposed between the second hollow cylinder and the second gas outlet actuated valve.

23. The gas compression system of claim 20 further comprising a second liquid inlet pressure sensor for measuring the pressure of liquid entering the second hollow cylinder and a second liquid outlet pressure sensor for measuring the pressure of liquid exiting the second hollow cylinder, the second liquid inlet pressure sensor being disposed between the second hollow cylinder and the second liquid inlet actuated valve and the second liquid outlet pressure sensor.

24. The gas compression system of claim 23 operated by a method comprising: a) closing the first liquid inlet actuated valve and the first liquid outlet actuated valve and/or the second liquid inlet actuated valve and the second liquid outlet actuated valve; b) opening the first gas inlet actuated valve and filling the first hollow cylinder to a predetermined low pressure and/or opening the second gas inlet actuated valve and filling the second hollow cylinder to the predetermined low pressure; c) closing the first gas inlet actuated valve when the pressure is equal to or greater than the predetermined low pressure and/or closing the second gas inlet actuated valve when the pressure is equal to or greater than the predetermined low pressure; d) opening the first liquid inlet actuated valve to introduce liquid into the first hollow cylinder and/or opening the second liquid inlet actuated valve to introduce liquid into the second hollow cylinder; e) closing the first liquid inlet actuated valve when the first predetermined high gas pressure is achieved and/or closing the second liquid inlet actuated valve when the first predetermined high gas pressure is achieved; f) opening the first gas outlet actuated valve to allow gas to flow to the gas collector tank and/or opening the second gas outlet actuated valve to allow gas to flow to the gas collector tank; g) closing the first gas outlet actuated valve when the pressure in the first hollow cylinder falls below a predetermined cylinder pressure and/or closing the second gas outlet actuated valve when the pressure in the first hollow cylinder falls below a predetermined cylinder pressure; h) opening the first liquid outlet actuated valve, followed by opening the first gas inlet actuated valve and/or opening the second liquid outlet actuated valve, followed by opening the second gas inlet actuated valve and/or; i) closing the first gas inlet actuated valve when the pressure in the first hollow cylinder is equal to or greater than the predetermined low pressure and/or closing the second gas inlet actuated valve when the pressure in the second hollow cylinder is equal to or greater than the predetermined low pressure; and j) cycling back to step d).

25. The gas compression system of claim 13, further comprising a radiator in fluid connection with the first cylinder bottom and the liquid holding tank, wherein the radiator cools liquid before it enters the liquid holding tank.

26. The gas compression system of claim 13, wherein the gas compression system is configured to compress the relatively uncompressed gas in the first hollow cylinder and the second hollow cylinder for a plurality of cycles.

27. The gas compression system of claim 13, wherein the gas compression system is configured to sequentially compress the relatively uncompressed gas in the first hollow cylinder and the second hollow cylinder for a plurality of cycles.

28. The gas compression system of claim 13, wherein the gas compression system is configured to compress the relatively uncompressed gas in the first hollow cylinder and the second hollow cylinder for a plurality of cycles in parallel.

29. A reaction assembly comprising: a reactor system that oxidizes a hydrocarbon-containing gas, and the gas compression system of claim 13 in fluid communication with the reactor system.

30. A gas compression system comprising: a first hollow cylinder; a gas source in fluid communication with the first hollow cylinder, the gas source providing a gas that enters the first hollow cylinder; a gas collector tank in fluid connection with the first hollow cylinder by an outlet line; a liquid holding tank that includes liquid in fluid communication with the first hollow cylinder; a pump in fluid connection with the liquid holding tank and the first hollow cylinder; an actuation system configured to control input of liquid and gas into the first hollow cylinder and output of gas and liquid from the first hollow cylinder; and a controller configured to control the actuation system, wherein the controller enables the pump to move liquid from the liquid holding tank into the first hollow cylinder at a higher pressure than the gas, thereby causing a liquid surface to move within the first hollow cylinder, compressing the gas, and wherein the controller enables release of compressed gas into the gas collector tank when its pressure exceeds a predetermined pressure.

Description

BRIEF DESCRIPTION OF THE DRAWINGS

[0034] FIG. 1 provides a schematic of the gas compression system having a single compression cylinder.

[0035] FIG. 2 illustrates a schematic illustration of a gas compression system with two independent compression organs.

[0036] FIG. 3 illustrates another schematic illustration of a gas compression system coupled to a reactor.

DETAILED DESCRIPTION

[0037] Reference will now be made in detail to presently preferred compositions, embodiments and methods of the present invention, which constitute the best modes of practicing the invention presently known to the inventors. The Figures are not necessarily to scale. However, it is to be understood that the disclosed embodiments are merely exemplary of the invention that may be embodied in various and alternative forms. Therefore, specific details disclosed herein are not to be interpreted as limiting, but merely as a representative basis for any aspect of the invention and/or as a representative basis for teaching one skilled in the art to variously employ the present invention.

[0038] Except in the examples, or where otherwise expressly indicated, all numerical quantities in this description indicating amounts of material or conditions of reaction and/or use are to be understood as modified by the word about in describing the broadest scope of the invention. Practice within the numerical limits stated is generally preferred. Also, unless expressly stated to the contrary: percent, parts of, and ratio values are by weight; the term polymer includes oligomer, copolymer, terpolymer, and the like; molecular weights provided for any polymers refers to weight average molecular weight unless otherwise indicated; the description of a group or class of materials as suitable or preferred for a given purpose in connection with the invention implies that mixtures of any two or more of the members of the group or class are equally suitable or preferred; description of constituents in chemical terms refers to the constituents at the time of addition to any combination specified in the description, and does not necessarily preclude chemical interactions among the constituents of a mixture once mixed; the first definition of an acronym or other abbreviation applies to all subsequent uses herein of the same abbreviation and applies mutatis mutandis to normal grammatical variations of the initially defined abbreviation; and, unless expressly stated to the contrary, measurement of a property is determined by the same technique as previously or later referenced for the same property.

[0039] It is also to be understood that this invention is not limited to the specific embodiments and methods described below, as specific components and/or conditions may, of course, vary. Furthermore, the terminology used herein is used only for the purpose of describing particular embodiments of the present invention and is not intended to be limiting in any way.

[0040] It must also be noted that, as used in the specification and the appended claims, the singular form a, an, and the comprise plural referents unless the context clearly indicates otherwise. For example, reference to a component in the singular is intended to comprise a plurality of components.

[0041] The term comprising is synonymous with including, having, containing, or characterized by. These terms are inclusive and open-ended and do not exclude additional, unrecited elements or method steps.

[0042] The phrase consisting of excludes any element, step, or ingredient not specified in the claim. When this phrase appears in a clause of the body of a claim, rather than immediately following the preamble, it limits only the element set forth in that clause; other elements are not excluded from the claim as a whole.

[0043] The phrase consisting essentially of limits the scope of a claim to the specified materials or steps, plus those that do not materially affect the basic and novel characteristic(s) of the claimed subject matter.

[0044] With respect to the terms comprising, consisting of, and consisting essentially of, where one of these three terms is used herein, the presently disclosed and claimed subject matter can include the use of either of the other two terms.

[0045] 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.

[0046] The term gas as used herein mean a single gaseous component or a mixture of gaseous components.

[0047] 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.

[0048] 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.

[0049] Throughout this application, where publications are referenced, the disclosures of these publications in their entirety are hereby incorporated by reference into this application to more fully describe the state of the art to which this invention pertains.

[0050] Referring to FIG. 1, a schematic of a gas compression system is provided. Gas compression system 10 includes the first hollow cylinder 12, which includes a first cylinder bottom 14 and a first cylinder top 16. The gas source 20 provides a relatively uncompressed gas in fluid communication through inlet line 22 with the first cylinder top 16 such that relatively uncompressed gas enters the first hollow cylinder 12 through the first cylinder top 16. Gas collector tank 24 is in fluid connection with the first cylinder top 16 by an outlet line 26. In this context, relatively uncompressed gas means gas that the gas is at a predetermined low pressure that is less than the compressed gas produced by gas compression system 10 (typically, the predetermined low pressure is at most 500, 200 or 100 psi). Liquid holding tank 30 includes liquid (e.g., water) in fluid communication with the first cylinder bottom 14. Pump 32 is in fluid connection with the liquid holding tank 30 and the first cylinder bottom 14. Actuation system 34 is configured to control the input of liquid and relatively uncompressed gas into the first hollow cylinder 12 and the output of compressed gas and liquid from the first hollow cylinder 12. Controller 38 is configured to control the actuation system 34. Controller 38 is configured to enable the pump 32 to move liquid from the liquid holding tank into the first hollow cylinder 12 through the first cylinder bottom 14 at a higher pressure than the relatively uncompressed gas, thereby causing a liquid surface 35 to move in a vertical direction (or along a center axis of the first hollow cylinder) within the first hollow cylinder 12, compressing the relatively uncompressed gas into compressed gas. The sequences of gas flow and liquid flow are controlled by a set of actuation valves in electrical communication with controller 38 as set forth below in more detail. The pressures in first hollow cylinder is read with a pressure sensor. Connections of various components to controller 38 are shown as dashed lines with angled terminators. Controller 38 enables the release of the compressed gas into gas collector tank 24 when its pressure is greater than the first predetermined high gas pressure. In a refinement, the first predetermined gas high pressure is greater than 1000 psi. In a further refinement, the first predetermined gas high pressure is greater than or e 2000 psi.

[0051] In another aspect, the relatively uncompressed gas (and therefore the compressed gas) is oxygen-containing gas such as air.

[0052] In another aspect, gas compression system 10 includes a pressure sensor 40 operatively associated with the outlet line 26 to measure the pressure of a compressed gas. In a refinement, gas compression system 10 includes a temperature sensor 41 operatively associated with the outlet line to measure the temperature of compressed gas. In a refinement, inlet line 22 can include flow meter 42, temperature sensor 43, and pressure sensor 44.

[0053] In another aspect, actuation system 34 includes a first gas inlet actuated valve 46 and a first gas outlet actuated valve 48 in electrical communication with the controller. First gas inlet actuated valve 46 is disposed between the first hollow cylinder 12 and the gas source 20 to control the entry of the relatively uncompressed gas into the first hollow cylinder 12. Similarly, the first gas outlet actuated valve 48 is disposed between the first hollow cylinder 12 and the gas collector tank 24 to control the exiting of the compressed gas from the first hollow cylinder 12.

[0054] In another aspect, actuation system 34 further includes a first liquid inlet actuated valve 50 and a first liquid outlet actuated valve 52 in electrical communication with the controller. First, liquid inlet actuated valve 50 is disposed between the first hollow cylinder 12 and the pump 32 to control the entry of the liquid into the first hollow cylinder 12. The first liquid outlet actuated valve 52 is disposed between the first hollow cylinder 12 and the liquid holding tank 30 to control the exiting of the liquid from the first hollow cylinder.

[0055] In another aspect, gas compression system 10 includes a first gas inlet pressure sensor 56 disposed between the first hollow cylinder 12 and the first gas inlet actuated valve 46 for measuring the pressure of gas entering the first hollow cylinder 12. Gas compression system 10 also includes a first gas outlet pressure sensor 58 between the first hollow cylinder and the first gas outlet actuated valve 48 12 measuring the pressure of gas exiting the first hollow cylinder 12. The first gas outlet pressure sensor 58 can be used to measure the gas pressure in the first hollow cylinder 12.

[0056] In another aspect, gas compression system 10 includes a first gas inlet check valve 66 disposed between the first hollow cylinder and the first inlet pressure sensor 56 for entry of the relatively uncompressed gas into the first hollow cylinder. Gas compression system 10 also includes a first gas outlet check valve 68 disposed between the first hollow cylinder 12 and the first outlet pressure sensor 58 for exiting the compressed gas from the first hollow cylinder 12.

[0057] In another aspect, gas compression system 10 includes a first liquid inlet pressure sensor 70 disposed between the first hollow cylinder 12 and the first liquid inlet actuated valve 50 measuring the pressure of liquid entering the first hollow cylinder 12. Gas compression system 10 also includes a first liquid outlet pressure sensor 72 disposed between the first hollow cylinder 12 and the first liquid outlet actuated valve 52 measuring the pressure of liquid exiting the first hollow cylinder 12.

[0058] In another aspect, gas compression system 10 includes a first liquid inlet check valve 76 disposed between the first hollow cylinder 12 and the first liquid inlet pressure sensor 70 for entry of the liquid into the first hollow cylinder 12. Gas compression system 10 also includes a first liquid outlet check valve 78 disposed between the first hollow cylinder 12 and the first liquid outlet pressure sensor 72 for exiting the liquid from the first hollow cylinder 12.

[0059] In another aspect, gas compression system 10 includes further including a radiator 80 in fluid connection with the first cylinder bottom 14 and the liquid holding tank 30. Radiator 80 cools liquid before it enters the liquid holding tank. Temperature sensor 82 measures the temperature of the liquid from the holding tank.

[0060] In another aspect, gas compression system 10 is operated as follows. To begin the process, close both the first liquid inlet actuated valve 50 and the first liquid outlet actuated valve 52 in step a). In step b), open the gas inlet actuated valve 46 (which was closed) and fill the first hollow cylinder 12 to a predetermined low pressure. The pressure of the first hollow cylinder is typically read with a pressure sensor (e.g., the first outlet pressure sensor 58). In step c), when the pressure is equal to or greater than the predetermined low pressure, close the gas inlet actuated valve 46. In step d), open the liquid inlet actuated valve 50. The pressure transmitter monitors the pressure to ensure that the pressure is equal to or greater than the first predetermined high gas pressure as measured by a pressure sensor (e.g., the first outlet pressure sensor 58). In step e), when the first predetermined high gas pressure is achieved, close the liquid inlet actuated valve 50. In step f), open the first gas outlet actuated valve 48 to allow the gas to flow to the gas collector tank 24. In step g), when the pressure in the first hollow cylinder 12 falls below a predetermined cylinder pressure, close the gas outlet actuated valve 48. In step h), open the liquid outlet actuated valve 52, followed by opening the gas inlet actuated valve 46. In step i), when the pressure is equal to or greater than the first predetermined low pressure as measured by a pressure sensor (e.g., the first outlet pressure sensor 58), close the gas inlet actuated valve 46. In step j), cycle back to step e). The gas compression system is cycled for any number of cycles to obtain the desired amount of compressed gas.

[0061] In another aspect, a reaction assembly includes a reactor system that oxidizes a hydrocarbon-containing gas, and the dual-cylinder gas compression system 10 in fluid communication with the reactor system. The reactor system is described below in detail.

[0062] In another aspect, the gas compression system further includes a second hollow cylinder 12 in fluid connection with the gas source 20, the liquid holding tank 30, and the pump 32. The second hollow cylinder 12 has a second cylinder bottom 14 and a second cylinder top 16. Controller 38 is further configured to enable the pump 32 to move liquid from the liquid holding tank 30 into the second hollow cylinder 12 at a higher pressure than the relatively uncompressed gas, thereby causing a liquid surface 35 to move in a vertical direction (or along a center axis of the second hollow cylinder) within the second hollow cylinder 12, compressing the relatively uncompressed gas into compressed gas. Controller 38 enables the release of the compressed gas into a gas collector tank 24 when its pressure is greater than the first predetermined high gas pressure in the second hollow cylinder 12.

[0063] Referring to FIG. 2, a schematic of a dual-column gas compression system, including two hollow cylinders, is provided. Gas compression system 10 includes first hollow cylinder 12 and second hollow cylinder 12. The first hollow cylinder 12 includes a first cylinder bottom 14 and a first cylinder top 16, while the second hollow cylinder 12 includes a second cylinder bottom 14 and a second cylinder top 16. Gas source 20 provides a relatively uncompressed gas to and is in fluid communication with the first cylinder top 16 and the second cylinder top 16 such that relatively uncompressed gas enters the first hollow cylinder 12 through the first cylinder top 16 and/or the second hollow cylinder 12 through the second cylinder top 16. In this context, relatively uncompressed gas means gas that is less than the compressed gas produced by gas compression system 10 (typically, at most 200 psi). Gas collector tank 20 in fluid connection with the first cylinder top and the second cylinder top by an outlet line 26. A liquid holding tank 30 that includes liquid in fluid communication with the first cylinder bottom and the second cylinder bottom. A pump 32 is in fluid connection with the liquid holding tank 30, the first cylinder bottom 14, and the second cylinder bottom 14. An actuation system 34 is configured to control input of liquid and relatively uncompressed gas into the first hollow cylinder 12 and second hollow cylinder 12 and output compressed gas and liquid from the first hollow cylinder 12 and the second hollow cylinder 12. Controller 38 is configured to control the actuation system. Controller 38 enables the pump 32 to move liquid from the liquid holding tank 30 into the first hollow cylinder 12 and/or the second hollow cylinder 12 at a higher pressure than the relatively uncompressed gas, thereby causing a liquid surface to move in a vertical direction (or along a center axis of the first hollow cylinder) within the first hollow cylinder 12 and/or the second hollow cylinder 12, compressing the relatively uncompressed gas into compressed gas. The Controller 38 enables the release of the compressed gas into a gas collector tank 24 when its pressure is greater than the first predetermined high gas pressure in either the first hollow cylinder 12 or the second hollow cylinder 12.

[0064] In another aspect, gas compression system 10 includes a pressure sensor 40 operatively associated with the outlet line 26 to measure the pressure of a compressed gas. In a refinement, gas compression system 10 includes a temperature sensor 41 operatively associated with the outlet line to measure the temperature of a compressed gas. In a refinement, inlet line 22 can include flow meter 42, temperature sensor 43, and pressure sensor 44.

[0065] In another aspect, actuation system 34 includes a first gas inlet actuated valve 46, a second gas inlet actuated valve 46, a first gas outlet actuated valve 48, and a second gas outlet actuated valve 48 in electrical communication with the controller. First gas inlet actuated valve 46 is disposed between the first hollow cylinder 12 and the gas source 20 to control the entry of the relatively uncompressed gas into the first hollow cylinder 12. The second gas inlet actuated valve 46 is disposed between the second hollow cylinder 12 and the gas source 20 to control the entry of the relatively uncompressed gas into the second hollow cylinder 12. The first gas outlet actuated valve 48 is disposed between the first hollow cylinder 12 and the gas collector tank 24 to control the exiting of the compressed gas from the first hollow cylinder 12. Similarly, the second gas outlet actuated valve 48 is disposed between the second hollow cylinder 12 and the gas collector tank 24 to control the exiting of the compressed gas from the second hollow cylinder 12.

[0066] In another aspect, actuation system 34 further includes a first liquid inlet actuated valve 50, a second liquid inlet actuated valve 50, a first liquid outlet actuated valve 52, and a second liquid outlet actuated valve 52 in electrical communication with the controller. The first liquid inlet actuated valve 50 is disposed between the first hollow cylinder 12 and pump 32 to control entry of the liquid into the first hollow cylinder 12. The first liquid outlet actuated valve 52 is disposed between the first hollow cylinder 12 and the liquid holding tank 30 to control the exiting of the liquid from the first hollow cylinder. Similarly, the second liquid inlet actuated valve 50 is disposed between the second hollow cylinder 12 and the pump 32 to control the entry of the liquid into the second hollow cylinder 12. The second liquid outlet actuated valve 52 is disposed between the second hollow cylinder 12 and the liquid holding tank 30 to control the exiting of the liquid from the second hollow cylinder.

[0067] In another aspect, gas compression system 10 includes a first gas inlet pressure sensor 56 disposed between the first hollow cylinder 12 and the first gas inlet actuated valve 46 for measuring the pressure of gas entering the first hollow cylinder 12. Gas compression system 10 also includes a first gas outlet pressure sensor 58 between the first hollow cylinder and the first gas outlet actuated valve 48 for measuring the pressure of gas exiting the first hollow cylinder 12. The first gas inlet pressure sensor 56 can also be used to measure the pressure of the first hollow cylinder 12.

[0068] In another aspect, gas compression system 10 includes a first gas inlet check valve 66 disposed between the first hollow cylinder and the first inlet pressure sensor 56 for entry of the relatively uncompressed gas into the first hollow cylinder. Gas compression system 10 also includes a first gas outlet check valve 68 disposed between the first hollow cylinder 12 and the first outlet pressure sensor 58 for exiting the compressed gas from the first hollow cylinder 12. In another aspect, gas compression system 10 includes a first liquid inlet pressure sensor 70 disposed between the first hollow cylinder 12 and the first liquid inlet actuated valve 50 measuring the pressure of liquid entering the first hollow cylinder 12. Gas compression system 10 also includes a first liquid outlet pressure sensor 72 disposed between the first hollow cylinder 12 and the first liquid outlet actuated valve 52 measuring the pressure of liquid exiting the first hollow cylinder 12.

[0069] In another aspect, gas compression system 10 includes a first liquid inlet check valve 76 disposed between the first hollow cylinder 12 and the first liquid inlet pressure sensor 70 for entry of the liquid into the first hollow cylinder 12. Gas compression system 10 also includes a first liquid outlet check valve 78 disposed between the first hollow cylinder 12 and the first liquid outlet pressure sensor 72 for exiting the liquid from the first hollow cylinder 12.

[0070] In another aspect, gas compression system 10 includes a second gas inlet pressure sensor 56 disposed between the second hollow cylinder 12 and the second gas inlet actuated valve 46 for measuring the pressure of gas entering the second hollow cylinder 12. Gas compression system 10 also includes a second gas outlet pressure sensor 58 between the second hollow cylinder 12 and the second gas outlet actuated valve 48 for measuring the pressure of gas exiting the first hollow cylinder 12. The second gas inlet pressure sensor 56 can be used to measure the pressure of the second hollow cylinder 12.

[0071] In another aspect, the gas compression system 10 includes a second gas inlet check valve 66 disposed between the second hollow cylinder 12 and a second inlet pressure sensor 56 for entry of the relatively uncompressed gas into the second hollow cylinder 12. Gas compression system 10 also includes a second gas outlet check valve 68 disposed between the second hollow cylinder 12 and the second outlet pressure sensor 58 for exiting the compressed gas from the second hollow cylinder 12.

[0072] In another aspect, gas compression system 10 includes a second liquid inlet pressure sensor 70 disposed between the second hollow cylinder 12 and the second liquid inlet actuated valve 50 measuring the pressure of liquid entering the second hollow cylinder 12. Gas compression system 10 also includes a second liquid outlet pressure sensor 72 disposed between the second hollow cylinder 12 and the second liquid outlet actuated valve 52 measuring the pressure of liquid exiting the second hollow cylinder 12.

[0073] In another aspect, gas compression system 10 includes a second liquid inlet check valve 76 disposed between the second hollow cylinder 12 and the second liquid inlet pressure sensor 70 for entry of the liquid into the second hollow cylinder 12. Gas compression system 10 also includes a second liquid outlet check valve 78 disposed between the second hollow cylinder 12 and the second liquid outlet pressure sensor 72 for exiting the liquid from the second hollow cylinder 12.

[0074] In another aspect, the gas compression system 10 includes a radiator 80 in fluid connection with the first cylinder bottom 14, the second cylinder bottom 14, and the liquid holding tank 30. Radiator 80 cools liquid before it enters the liquid holding tank. Temperature sensor 82 measures the temperature of the liquid from the holding tank.

[0075] In another aspect, the techniques described herein relate to a gas compression system, wherein the compression system is configured to compress the relatively uncompressed gas in the first hollow cylinder 12 and the second hollow cylinder 12 for a plurality of cycles. In a refinement, the techniques described herein relate to a gas compression system 10 configured to sequentially compress the relatively uncompressed gas in the first hollow cylinder 12 and the second hollow cylinder 12 for a plurality of cycles. In a refinement, a gas compression system 10 is configured to compress the relatively uncompressed gas in the first hollow cylinder and the second hollow cylinder for a plurality of cycles in parallel.

[0076] In another aspect, a method of operating gas compression system 10 includes steps of filling the first hollow cylinder and/or the second hollow cylinder with the relatively uncompressed gas, filling the first hollow cylinder and/or the second hollow cylinder with liquid to compress the relatively uncompressed gas, and then collecting the compressed gas. In particular, gas compression system 10 is operated by a method comprising the following steps. Initially, close the first liquid inlet actuated valve 50 and the first liquid outlet actuated valve 52, and/or the second liquid inlet actuated valve 50 and the second liquid outlet actuated valve 52 in step a). In step b), open the first gas inlet actuated valve 46 and fill the first hollow cylinder 12 to a predetermined low pressure, and/or open the second gas inlet actuated valve 46 and fill the second hollow cylinder 12 to the predetermined low pressure. In step c), once the pressure is equal to or greater than the predetermined low pressure, close the first gas inlet actuated valve 46 and/or the second gas inlet actuated valve 46. In step d), open the first liquid inlet actuated valve 50 to introduce liquid into the first hollow cylinder 12, and/or open the second liquid inlet actuated valve 50 to introduce liquid into the second hollow cylinder 12. In step e), close the first liquid inlet actuated valve 50 when the first predetermined high gas pressure is achieved, and/or close the second liquid inlet actuated valve 50 when the first predetermined high gas pressure is achieved. In step f), open the first gas outlet actuated valve 48 to allow gas to flow to the gas collector tank 24, and/or open the second gas outlet actuated valve 48 to allow gas to flow to the gas collector tank 24. In step g), close the first gas outlet actuated valve 48 when the pressure in the first hollow cylinder 12 falls below a predetermined cylinder pressure, and/or close the second gas outlet actuated valve 48 when the pressure in the second hollow cylinder 12 falls below a predetermined cylinder pressure. In step h), Open the first liquid outlet actuated valve 52, followed by opening the first gas inlet actuated valve 46, and/or open the second liquid outlet actuated valve 52, followed by opening the second gas inlet actuated valve 46. In step i), Close the first gas inlet actuated valve 46 when the pressure in the first hollow cylinder 12 is equal to or greater than the predetermined low pressure (typically below 200 or 100 psi), and/or close the second gas inlet actuated valve 46 when the pressure in the second hollow cylinder 12 is equal to or greater than the predetermined low pressure. Finally, in step j), cycle back to the step of opening the liquid inlet actuated valve (i.e., step d)), continuing the process for any number of cycles to obtain the desired amount of compressed gas.

[0077] In another embodiment, a reaction assembly includes a reactor system that oxidizes a hydrocarbon-containing gas, and the gas compression system as set forth above in fluid communication with the reactor system. FIG. 3 illustrates an exemplary schematic in which reactor system 100 is coupled to a gas compression system 10 or 10 described above. FIG. 3 details the reactor's inputs and outputs. Reactor system 100 includes reactor 102 that includes a reaction zone provided with a device for introducing a heated hydrocarbon-containing gas stream 104 and a device 10 or 10 for introducing an oxygen-containing compressed gas. In a refinement, the oxygen-containing compressed gas preferably has greater than 80% oxygen content to reduce the accumulation of inert gases during the recycling process.

[0078] The reactor 102 further has a regulation zone 106 provided with an optional device for introducing a cold hydrocarbon-containing gas stream to reduce the temperature of the reaction during the apparatus's operation. In addition, reactor 102 is provided with thermal pockets for controlling and regulating temperatures in corresponding zones, for example, with thermocouples.

[0079] The apparatus has a device for cooling the reaction mixture before separation. Additionally, the partial condenser 110 incorporates a gas-liquid heat exchanger to further reduce the temperature of the products. The condenser 110 separates liquid and alcohols from a hydrocarbon-carbon dioxide mixture. The partial condenser 110 is preferably isobaric, as opposed to isothermal to avoid pressure losses. The product stream enters, and the liquid stream and gaseous stream exist in the condenser 110.

[0080] Block 114 represents equipment that is configured to separate contaminants and products from a hydrocarbon-containing recycle gas component. In this regard, block 114 is configured to remove carbon dioxide from the reduced product stream. The equipment 114 can take the form of a purge valve, membrane separator, or an absorber. It is envisioned that equipment 114 can be used to regulate the percentage of other non-reactive components, such as nitrogen, with, for example, a purge valve.

[0081] In the event the system is configured to recover formaldehyde, the gaseous reduced product stream leaves the condenser 110 and is passed to the scrubber 120. Other potential methods that can be utilized use absorbents such as various amines to remove CO.sub.2 and 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 liquid, 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 stream 126 is completely regenerated by the formaldehyde distillation column 122. Optionally, the stream 126 from the scrubber 120 can be passed through the condenser 110 to provide cooling of the product stream and preheating of the methanol recycle to improve the energy efficiency of the formaldehyde distillation column 122.

[0082] The reactor 102 is connected with an optional compressor 128 and heater 130 for the supply of compressed and heated oxygen-containing gas. The raw hydrocarbon-containing gas is mixed with cleaned hydrocarbon gas from the scrubber 120 and is heated using a heater 134. In the event the raw hydrocarbons have a high CO.sub.2 content, the raw hydrocarbons can be mixed with the reduced product hydrocarbon stream from the condenser 110 prior to the entry of the scrubber 120 for removal of contaminant gases prior to entering the reactor.

[0083] The apparatus further has a unit for rectification of methanol which includes a flash drum 140, rectification column 142, and a vessel 146 from which methanol is supplied to storage or further processing. This rectification column 142 is used to separate methanol (light-key component) from ethanol (heavy-key component) and liquid (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. Stream 150 enters the column and the distillate, stream 152, and bottoms, stream 154, exit the column in liquid phase. Stream 154 has 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 (stream 160). In this manner, some of the ethanol is recovered before the remainder is discarded in the liquid waste stream.

[0084] A flash drum 140 is disposed between column 142 and condenser 110 for the removal of CO2 and formaldehyde from the liquid product stream. The purpose of the flash drum 140 is to drop the pressure to an appropriate level before entry into the methanol rectification column 142 and to substantially remove any dissolved gases, typically CO2 and formaldehyde, from the liquid product stream.

[0085] 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 heater 134, in which it is heated to temperature 146-470 C. The heated hydrocarbon-containing gas is then supplied into the reaction zone of the reactor 102. 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 compressor 128 also into the reaction zone of the reactor 102. Oxidation reaction takes place in the reaction zone of the reactor 102. 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 N.sub.2 within 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 N.sub.2 entering the system.

[0086] 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 reactor 102. This stream is regulated by the regulating device 164, 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.

[0087] The reaction mixture is supplied into the heat exchanger 166 for transfer of heat to the reactor input stream from the reaction mixture exiting the reactor, and after further cooling is supplied within partial condenser 110. Separation of the mixture into high and low-volatility components (dry gas and raw liquid, respectively) is performed in the partial condenser 110, which may absorb at least some of the formaldehyde into the raw liquid stream as desired. The dry gas is forwarded to a scrubber 120, while the raw liquids from the condenser 110 are supplied to the flash drum 140.

[0088] The scrubber 120 functions to remove the CO.sub.2 and formaldehyde from the dry gas stream. In this regard, the scrubber 120 uses both H.sub.2O and methanol at between 7-8 MPa pressure and between about 0 C. and about 50 C. to absorb CO.sub.2 and formaldehyde. Once the CO.sub.2 and 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.

[0089] The rectification column is used to separate carbon dioxide (non-key component) and formaldehyde (light-key component) from methanol (heavy-key component) and liquid (non-key component). The pregnant methanol stream 126 enters the rectification column and is separated into a formaldehyde distillate, stream 170, and a bottoms stream, stream 172. 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 liquid). 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. Stream 172 is supplemented by stream 176 so as to replace any methanol that was transferred to the distillate stream, stream 170. Combining stream 176 and stream 172 results in stream 180, which then returns to the scrubber 120 as a regenerated methanol absorbent. Meanwhile, the formaldehyde distillate, stream 170, combines with the vapors from such a flash drum 140, and stream 182 to form a mixture of formaldehyde, methanol, and carbon dioxide.

[0090] The formaldehyde, liquid, methanol, and CO.sub.2 removed by scrubber 120 are passed to formaldehyde rectification column 122. Column 122 removes formaldehyde and CO.sub.2 from the methanol-liquid stream. Small amounts of methanol are combined with produced methanol and are inputted into the scrubber 120 to remove additional amounts of CO.sub.2 and formaldehyde from the reduced hydrocarbon stream. Free or non-aqueous formaldehyde is allowed to remain in the gas phase by operation of the isobaric condenser 110. The liquid methanol product stream, or raw liquids, would then comprise methanol, ethanol, and liquid by allowing formaldehyde to remain in the gaseous stream. In this case, the liquid stream exiting the isobaric condenser 110 can bypass the formaldehyde rectification portion of the process and enter the methanol rectification column after having optionally passed through the flash drum 140.

[0091] While exemplary embodiments are described above, it is not intended that these embodiments describe all possible forms of the invention. Rather, the words used in the specification are words of description rather than limitation, and it is understood that various changes may be made without departing from the spirit and scope of the invention. Additionally, the features of various implementing embodiments may be combined to form further embodiments of the invention.