Enhanced Yield and Methane Efficiency in Acetylene Production via Byproduct Syngas Recirculation

To overcome the yield limitations of conventional methane pyrolysis for acetylene production, this study proposes a process featuring recirculation of byproduct syngas. The reactor performance was evaluated via computational fluid dynamics (CFD) simulations coupled with a modified GRI-Mech 3.0 kinetic mechanism. The results demonstrate that the proposed process achieves a synergistic enhancement in both acetylene yield and feedstock utilization efficiency. Compared with the conventional partial oxidation (POX) process, the proposed process achieves a 25% increase in acetylene yield along with a 17% reduction in specific methane consumption. Furthermore, compared with the methane-fueled partially decoupled process (PDP), the proposed process delivers a 44% reduction in total methane consumption. By reconfiguring the utilization of byproduct syngas, the proposed process not only realizes efficient valorization of byproduct streams but also provides a new technological paradigm for resource-efficient and low-carbon acetylene production.