Flexible preparation system and method for sustainable aviation fuel

Abstract

The invention provides a flexible preparation system and method for sustainable aviation fuel, and the system comprises a green power supply module which is used for outputting fluctuating green electric energy; the process execution device is connected with the green power supply module and comprises five process modules, namely an air carbon capture module, a co-electrolysis module, a Fischer-Tropsch synthesis module, a hydrogen production module and a hydrogenation refining module; the data acquisition module is used for acquiring the temperature, the pressure, the liquid level, the raw material input flow and / or the product output flow of each process module in the process execution device; and the decision control module is used for predicting the future power supply condition of the green electricity based on the historical weather data of the green electricity location, adjusting the distribution of the power in each process module according to the future power supply condition, and adjusting the temperature, pressure and / or raw material input flow in each process module. According to the invention, the cost, the reliability, the operation and maintenance performance, the product quality and the green power utilization rate can be substantially improved at the same time, and the flexible and stable operation of the system under the green power condition is realized.

Description

Technical Field

[0001] This invention relates to the field of sustainable aviation fuel preparation technology, and in particular to a flexible preparation system and method for sustainable aviation fuel. Background Technology

[0002] Sustainable aviation fuel (SAF) is considered a key pathway to achieving the aviation industry's 2050 net-zero emissions target due to its good compatibility with existing aviation infrastructure and its enormous emissions reduction potential (theoretically, emissions reductions of over 80% over its entire life cycle). In particular, the e-SAF preparation process, which uses direct carbon capture (DAC) as its source and combines carbon dioxide reduction and conversion, Fischer-Tropsch synthesis, and hydrorefining, is becoming a mainstream chemical and refining technology for the large-scale utilization of renewable energy green electricity.

[0003] However, renewable energy sources (such as wind and solar power) are characterized by significant intermittency and volatility, with their output significantly affected by climate and diurnal cycles, exhibiting instability both temporally and spatially. Traditional e-SAF synthesis processes have extremely high requirements for continuous energy supply, reactor operational stability, and catalyst operating condition balance, making them ill-suited to the fluctuating characteristics of renewable energy sources. This leads to severe supply-demand mismatches in large-scale applications. Without effective regulation mechanisms, this can easily result in frequent plant start-ups and shutdowns, catalyst deactivation, decreased energy efficiency, and even system instability.

[0004] Specifically, existing e-SAF production systems face several key challenges: First, they generally employ rigid structural designs. Traditional pathways such as DAC, CO2 reduction, Fischer-Tropsch synthesis, and hydrorefining rely on stable energy and feedstock supplies. Units are connected by fixed flow rates and loads, lacking buffering and regulation capabilities. This makes them ill-suited for rapid response to power fluctuations, leading to frequent start-ups and shutdowns, disrupted thermal balance, and compromised operational safety and stability. Second, traditional catalysts perform optimally within specific temperature, pressure, and atmosphere windows. Under fluctuating conditions, they are prone to runaway reaction conditions. Sudden temperature drops or excessive heating rates can cause catalyst poisoning, carbon buildup, coking, and even structural damage, reducing catalytic activity and lifespan. Frequent start-ups and shutdowns also cause repeated stress shocks to the catalyst, accelerating deactivation. Furthermore, in existing e-SAF systems, intermediate products such as syngas, hydrogen, and Fischer-Tropsch waxes are often produced and used immediately, lacking effective storage and buffering devices. This results in highly coupled upstream and downstream operations. When fluctuations in green electricity cause stagnation or changes in capacity at one stage, these effects are transmitted to the entire system, exacerbating operational risks. Distillation control strategies also struggle to support flexible scheduling. Traditional systems are suited for full-load or quasi-steady-state operation, but they cannot cope with the nonlinear dynamic disturbances caused by frequent changes in operating conditions. Under low-load or fluctuating conditions, problems such as decreased heat exchange efficiency, separation tower instability, and difficulty in liquid level control can easily occur, leading to a decline in product quality or even process interruption. Finally, the system's load regulation capacity is limited. Constrained by process safety boundaries, the system's load increase and decrease rates are relatively low (e.g., +15% / h, -25% / h). If the load increases too quickly, it can easily cause local overheating of the catalyst and thermal stress damage. If the load decreases too quickly, it may lead to reaction interruption and enhanced side reactions, making it unable to adapt to the rapid fluctuations of renewable energy on an hourly or even minute-by-minute scale.

[0005] Therefore, in the context of promoting the development of green aviation fuel, it is urgent to carry out systematic research under the conditions of renewable energy driving, focusing on breakthroughs in key technologies for the coupling and integration and process control of large-scale carbon capture, carbon conversion and e-SAF synthesis processes adapted to power fluctuation characteristics, and to build a flexible operating system with flexible response capabilities, so as to achieve deep integration of renewable energy and e-SAF synthesis process, improve the energy efficiency, stability and economy of the overall system, and help achieve carbon emission reduction targets in the aviation field. Summary of the Invention

[0006] The purpose of this invention is to provide a flexible preparation system and method for sustainable aviation fuel, which integrates green electricity output, hardware zoning adjustment of process equipment, process path optimization, and intelligent control strategies to solve the problems of rigid hardware, fragile catalysts, and poor system adjustability in existing systems. It can achieve substantial and verifiable improvements in cost, reliability, maintainability, product quality, and green electricity utilization simultaneously, and realize the flexible and stable operation of the sustainable aviation fuel preparation system under green electricity conditions.

[0007] This invention proposes a flexible preparation system for sustainable aviation fuel, comprising:

[0008] Green power module, used to output fluctuating green electricity;

[0009] The process execution unit, connected to the green power supply module, includes five process modules: an air carbon capture module, a co-electrolysis module, a Fischer-Tropsch synthesis module, a hydrogen production module, and a hydrorefining module. The air carbon capture module captures carbon dioxide from the air and consists of several solid collectors connected in parallel, each of which can be started and stopped independently. The co-electrolysis module, connected to the air carbon capture module, consists of several co-electrolyzers connected in parallel, each of which can be started and stopped independently. It is used to electrolyze carbon dioxide and water to produce syngas containing carbon monoxide and hydrogen. The Fischer-Tropsch synthesis module, connected to the co-electrolysis module, consists of several microreactors connected in parallel and / or in series, each of which can be started and stopped independently. Each microreactor contains a Fischer-Tropsch synthesis catalyst to convert syngas into oil and wax. The hydrogen production module consists of several electrolyzers connected in parallel, each of which can be started and stopped independently. It is used to electrolyze water to produce hydrogen. The hydrorefining module, connected to the Fischer-Tropsch synthesis module and the hydrogen production module, is used to convert oil and wax into aviation fuel through a catalytic hydrogenation reaction. The data acquisition module is used to collect the temperature, pressure, liquid level, raw material input flow rate and / or product output flow rate of each process module in the process execution device; The decision control module predicts the future power supply of green energy based on historical weather data and future weather forecast data of the green energy location, and adjusts the power distribution in each process module according to the future power supply. It also regulates the temperature, pressure and / or raw material input flow in each process module, and regulates the actual operating load of each process module within a set range by controlling the start and stop of the parallel components in each process module.

[0010] In one embodiment, the solid traps all adsorb carbon dioxide from the air using porous solid adsorbent materials; The hydrorefining module includes several hydrorefining reactors and a distillation column. The hydrorefining reactors are used to react oil and wax with hydrogen to generate a mixed fuel. The hydrorefining reactors are connected in parallel and / or in series. The distillation column is connected to the hydrorefining reactors and is used to fractionate the mixed fuel into a single fuel.

[0011] In one embodiment, the decision control module also controls the start-up and shutdown, adsorption duration and / or desorption duration of each solid collector in the air carbon capture module, the start-up and shutdown of each co-electrolyzer in the co-electrolyzer module, the feed rate and temperature of carbon dioxide and water, the start-up and shutdown, temperature, pressure and syngas flow rate of each microreactor in the Fischer-Tropsch synthesis module, the start-up and shutdown and pressure of each electrolyzer in the hydrogen production module, the circulation volume of circulating hydrogen, the input flow rate of oil and wax, and the input flow rate of hydrogen in the hydrogenation reactor in the hydrorefining module, and the temperature, pressure and feed flow rate in the distillation column, based on future power supply conditions.

[0012] In one embodiment, the microreactor is provided with serpentine, fishbone, and / or Tesla one-way valve-shaped microchannels, and the Fischer-Tropsch synthesis catalyst is coated on the inner wall of the microchannel or disposed in the microchannel by being loaded on a honeycomb carrier or a spherical powder carrier with a nanoporous structure.

[0013] In one embodiment, the process execution apparatus further includes an intermediate product storage module, which includes a carbon dioxide storage tank, a syngas storage tank, an oil and wax storage tank, and a hydrogen storage tank. The carbon dioxide storage tank is located between the air carbon capture module and the co-electrolysis module and is used to store carbon dioxide; The syngas storage tank is located between the co-electrolysis module and the Fischer-Tropsch synthesis module and is used to store syngas composed of carbon monoxide and hydrogen. The oil and wax storage tank is located between the Fischer-Tropsch synthesis module and the hydrorefining module and is used to store oil and wax. The hydrogen storage tank is located between the hydrogen production module and the hydrogen refining module and is used to store hydrogen. The decision control module also controls the liquid level in the intermediate product storage module tank and the opening and closing of the inlet and outlet valves.

[0014] In one embodiment, the flexible preparation system for sustainable aviation fuel further includes an energy storage device connected to the green power module for storing green electrical energy. The energy storage device may be in the form of battery energy storage, compressed air energy storage, and / or hydrogen energy storage.

[0015] This invention also proposes a flexible preparation method for sustainable aviation fuel, which is applied to the flexible preparation system for sustainable aviation fuel as described above, and includes the following steps: Collect historical weather data for the locations of green electricity sources; Predict the future power supply of green energy based on historical weather data and future weather forecast data of the locations where green energy is located; Collect temperature, pressure, liquid level, raw material input flow rate and / or product output flow rate of each process module in the sustainable aviation fuel preparation process; The allocation of green electricity in the five process modules of sustainable aviation fuel preparation process—air carbon capture module, co-electrolysis module, Fischer-Tropsch synthesis module, hydrogen production module, and hydrogen refining module—will be adjusted based on future power supply conditions and collected process data. Control and regulate the temperature, pressure, and / or raw material input flow rate in each process module.

[0016] In one embodiment, the prediction of future power supply based on historical weather data and future weather forecast data of the location of the green power plant specifically includes: AI models are used to identify time-series patterns and fluctuation characteristics of historical green electricity generation output. By combining meteorological information and seasonal patterns to predict the future power supply of green electricity, the power generation forecast curves for each time period of the day are obtained.

[0017] In one embodiment, the flexible preparation method for sustainable aviation fuel further includes: adjusting the actual operating load of each process module within the safe load range of each process module by controlling the number of devices turned on in each process module according to future power supply conditions.

[0018] In one embodiment, during the sustainable aviation fuel production process, the operating load of the Fischer-Tropsch synthesis module is twice that of the hydrorefining module; The minimum load for the Fischer-Tropsch synthesis module is 40%, and the minimum load for the hydrorefining module is 80%. The output of the Fischer-Tropsch synthesis module at its minimum load is matched with the amount of feed required for the hydrorefining module at its minimum load.

[0019] Compared with existing technologies, the advantages of the flexible preparation system and method for sustainable aviation fuel of the present invention are as follows:

[0020] 1) This invention combines AI and big data technologies to systematically analyze and model the output of renewable fluctuating energy sources such as wind and solar power. Through comprehensive processing of historical data, meteorological information, seasonal patterns, and equipment operating characteristics over many years, the AI ​​model can identify the time-series patterns and fluctuation characteristics of wind and solar power output. Based on this, it can make short-term and medium-to-long-term predictions of future output. The AI ​​can train the prediction model to address these differences, thereby obtaining a high-precision prediction curve of the total power generation for each time period of the day. Accurate prediction can not only provide feedforward signals for the start-up, shutdown, and load adjustment of modular devices such as electrolyzers, DACs, and Fischer-Tropsch synthesizers, but also help the system formulate flexible operating strategies, achieve dynamic matching of energy supply and demand, maximize the utilization efficiency of renewable energy, and improve the flexibility and economy of the overall system.

[0021] 2) This invention utilizes a comprehensive technical solution of "modularization + buffering (electric / thermal / gas / liquid) + reactor flexibility (microreactor / structured catalyst) + multivariable intelligent control" to synergistically eliminate the three core defects of traditional e-SAF systems—rigidity, fragility, and coupling—through physical, process, and control pathways. On the one hand, relying on modular design, the configuration of energy storage devices and intermediate product storage modules, combined with rhythmic operation and intelligent scheduling mechanisms, it achieves decoupling and operational flexibility between various devices, effectively solving the problems of poor adaptability to power fluctuations and difficulty in matching with fluctuating energy sources in traditional systems. On the other hand, through multi-dimensional... Technological collaboration brings several significant advantages: In terms of economic risk control, it can support phased construction and phased commissioning, reducing one-time over-investment and lowering capital and financial risks; in terms of operational reliability, the failure or shutdown of some modules will not lead to the paralysis of the entire plant, making maintenance more convenient and significantly improving the reliability and availability of system operation; in terms of cost and green energy utilization, it can operate and store energy in a concentrated manner when electricity prices are low and green energy output is high, significantly improving the green energy consumption rate, while optimizing unit product energy consumption and reducing operating costs; in terms of product quality, downstream industries can obtain a more stable raw material flow, effectively reducing product index fluctuations and ensuring stable product quality.

[0022] 3) This invention, by optimizing process conditions, adopting a staged heat and pressure maintenance strategy, and combining flexible reactor design (such as the microreactor used in Fischer-Tropsch synthesis) and a soft-start strategy, can effectively solve the core problem of poor catalyst resistance to fluctuations in traditional systems. It avoids catalyst deactivation caused by thermomechanical shock, local overheating or cooling, carbon deposition, and reduction / oxidation cycles, significantly extending the catalyst's operating cycle and service life, thereby reducing the frequency of catalyst replacement and lowering related maintenance costs. On the other hand, it can also reduce the occurrence of side reactions and carbon deposition caused by temperature fluctuations, improving the selectivity and yield of the target product. At the same time, even in the face of frequent start-ups or load changes caused by green electricity fluctuations, the catalyst can maintain long-term performance stability without sacrificing operating performance, fully adapting to the fluctuation characteristics of renewable energy, and providing key support for the stable operation of the e-SAF synthesis system driven by fluctuating energy.

[0023] 4) This invention, by configuring medium and large-sized gas and liquid storage tanks and combining them with a solid adsorbent for "carbon holding" as a buffering medium, ensures a continuous supply of raw materials for each process stage while allowing flexible adjustment of the operating cycle according to the operating characteristics of different processes, thus achieving decoupling and stable operation of the production system. Furthermore, this buffering system effectively compensates for the lack of intermediate buffering in traditional e-SAF systems, bringing significant advantages in several aspects. It greatly improves system stability, reduces the risk of the entire chain operation caused by upstream capacity fluctuations, avoids equipment wear and damage to catalysts caused by frequent start-ups and shutdowns, and extends the service life of equipment and catalysts. It significantly enhances operational flexibility and reduces scheduling costs (eliminating the need for excessive expansion of process units to cope with short-term power peaks and valleys). Simultaneously, it improves resource utilization, reduces raw material waste and energy consumption, and further saves on raw material procurement and energy consumption costs.

[0024] 5) This invention achieves dynamic and coordinated control of key parameters such as temperature, pressure, and flow rate through multi-variable linkage control (e.g., MPC), real-time feedback optimization, and adaptive loop adjustment mechanisms. This ensures stable and efficient system operation even under unsteady conditions. This control strategy, combined with online analysis and multiple operating schemes, maintains stable product indicators even with small load fluctuations, effectively preventing problems such as tray drying or flooding caused by low loads. It also reduces manual debugging and trial-and-error time, improving system automation and operational safety. Furthermore, this intelligent control method avoids over-designing reboilers / condensers to adapt to extreme loads, thereby reducing equipment investment costs.

[0025] 6) This invention significantly improves the system's response speed, safety, and ramp-up flexibility during load changes by employing miniaturized devices, modular partitioning, and efficient response strategies. Specifically, through parallel connection of miniaturized units, partitioned ramp-up strategies, and preheating and segmented load increase rules, the system's load regulation capability is greatly enhanced, enabling it to effectively respond to minute-level or hour-level power fluctuations and participate in grid peak shaving and frequency regulation, thereby improving the efficiency of green electricity utilization. Simultaneously, this design effectively reduces equipment fatigue and catalyst mechanical damage caused by rapid load increases and decreases, further ensuring the long-term reliability and economy of the system. Attached Figure Description

[0026] Figure 1 This is a schematic diagram of the structure of a flexible preparation system for sustainable aviation fuel according to an embodiment of the present invention;

[0027] Figure 2 This is a schematic diagram of the process execution device in a flexible preparation system for sustainable aviation fuel according to an embodiment of the present invention;

[0028] Figure 3This is a schematic diagram of the control system for a flexible preparation system of sustainable aviation fuel according to an embodiment of the present invention;

[0029] Figure 4 This is a bar chart showing the output of wind and solar power in Hami region over a 24-hour period.

[0030] Figure Labels

[0031] 100. Green power supply module; 200. Process execution device; 201. Air carbon capture module; 202. Co-electrolysis module; 203. Fischer-Tropsch synthesis module; 204. Hydrogen production module; 205. Hydrogenation refining module; 206. Intermediate product storage module; 300. Data acquisition module; 400. Decision control module; 500. Energy storage device. Detailed Implementation

[0032] To make the objectives, technical solutions, and advantages of this invention more readily understood, the invention will be further described in detail below with reference to the accompanying drawings and specific embodiments. It should be noted that while many specific details are set forth in the following description to provide a thorough understanding of the invention, the invention can also be implemented in other ways different from those described herein. Those skilled in the art can make similar extensions without departing from the spirit of the invention; therefore, the invention is not limited to the specific embodiments disclosed below.

[0033] Secondly, the phrase "an embodiment" or "a particular embodiment" in this application refers to a specific feature, structure, or characteristic that can be included in at least one implementation of the present invention. The phrases "in one embodiment" and "a particular embodiment" appearing in different places in this specification do not all refer to the same embodiment, nor are they embodiments that are mutually exclusive, either alone or selectively, with other embodiments. The terms "comprising" or "including" indicate the presence of the claimed feature but do not exclude the presence of one or more other features. The term "and / or" as used in this application includes any and all combinations of one or more of the related listed items.

[0034] This invention proposes a flexible production system for sustainable aviation fuel, primarily applicable to scenarios requiring fluctuating electricity (such as wind power, photovoltaic power, and other green electricity). The system includes a green electricity power module 100, a process execution device 200, a data acquisition module 300, a decision control module 400, and an energy storage device 500. (See also...) Figure 1The green power module 100 is used to output fluctuating green electricity, such as wind power and photovoltaic power. The energy storage device 500 is connected to the green power module 100 and is used to store the surplus fluctuating electricity generated by green electricity. The energy storage device can be in the form of battery energy storage, compressed air energy storage, hydrogen energy storage (equipped with a fuel cell), or any combination of batteries, compressed air, and hydrogen. The hydrogen energy storage device can be integrated with a hydrogen storage tank. The energy storage device is also connected to a decision control module, and its opening and closing are controlled by the decision control module. The process execution device 200 is connected to the green power module 100, see [link to documentation]. Figure 2 The system comprises five process modules: an air carbon capture module 201 (DAC), a co-electrolysis module 202 (Co-Elec), a Fischer-Tropsch synthesis module 203 (FTS), a hydrogen production module 204 (Elec), and a hydrorefining module 205 (Hydro+Dist). The air carbon capture module 201 captures carbon dioxide from the air. The co-electrolysis module 202, connected to the air carbon capture module 201, electrolyzes carbon dioxide (CO2) and water (H2O) to produce syngas, which consists of carbon monoxide (CO) and hydrogen (H2). The Fischer-Tropsch synthesis module 203, connected to the co-electrolysis module 202, converts the syngas into oils and waxes. The hydrogen production module 204 electrolyzes water to produce hydrogen. The hydrorefining module 205, connected to the Fischer-Tropsch synthesis module 203 and the hydrogen production module 204, converts oils and waxes into aviation fuel through a catalytic hydrogenation reaction. The data acquisition module 300 is used to collect data on temperature, pressure, liquid level, raw material input flow rate, and / or product output flow rate of each process module in the process execution unit 200. Specifically, thermocouples, resistance temperature detectors (RTDs), or temperature transmitters are generally used to collect temperature signals, pressure transmitters to collect pressure signals, and turbine flow meters or electromagnetic flow meters to collect raw material input or product output flow signals. The decision control module 400 uses an AI big data model to predict the future power supply of green energy based on historical weather data (sunlight and / or wind power, etc.) of the green energy location, and adjusts the power distribution in each process module according to the future power supply situation, dynamically linking and regulating the temperature, pressure, and / or raw material input flow rate in each process module. Multi-variable dynamic linkage regulation refers to keeping the temperature and pressure within the process section constant (maintaining high catalyst activity and conversion rate), connecting upstream and downstream processes through changes in flow parameters, and controlling the supply of utilities such as cooling water, steam, and electricity (mainly pumps, compressors, and other moving equipment) according to load changes in each process section. For the entire process, the decision control module mainly adjusts the output changes of each process segment based on the future (planning could be done in the next day or two, or even a week) green energy situation, and thus controls changes in utilities. The underlying logic is based on load following source, matching process output according to green energy input, with each process module fluctuating within the range of its respective equipment requirements, thereby completing the overall material flow.

[0035] The decision control module 400 can be specifically divided into an external input layer, a data acquisition and optimization layer, and a decision control layer. (See also...) Figure 3 The external input layer uses an AI model to predict future power supply from green energy sources based on historical weather data and future weather forecasts of the green energy location. The data acquisition and optimization layer receives process data from the data acquisition module 300, including temperature, pressure, liquid level, raw material input flow rate, and / or product output flow rate from each process module. The decision control layer, based on the future power supply situation and the collected process data, generates load scheduling plans for each process module and allocates power. Simultaneously, it dynamically and collaboratively controls parameters such as temperature, pressure, and flow rate in each process module to achieve steady-state operation of the sustainable aviation fuel flexible preparation system. The decision control module 400 predicts the future power supply of green energy based on historical weather data and future weather forecast data of the location of green energy. Specifically, it includes: systematically analyzing and modeling the output of renewable energy sources such as wind power and photovoltaics in the past; comprehensively processing historical data, meteorological information, seasonal patterns and equipment operation characteristics over many years; and identifying the time series patterns and fluctuation characteristics of green energy power generation output such as wind and solar power through AI models. For example, there are significant differences in solar radiation intensity, day and night duration and wind speed distribution in different seasons and months. Based on this, it makes short-term and medium-to-long-term predictions of future output, thereby obtaining a high-precision prediction curve of the total power generation at each time period of the day.

[0036] An embodiment of the present invention comprises an air carbon capture module 201 (DAC) consisting of several solid traps connected in parallel, each starting and stopping independently. All traps adsorb carbon dioxide from the air using functionalized porous solid adsorbent materials (such as amino-modified silica gel, porous carbon materials, etc.). Specifically, the functionalized porous solid adsorbent materials can adsorb carbon dioxide from the air at room temperature or medium-low temperatures, and then utilize solar energy or waste heat to achieve carbon dioxide desorption and regeneration through heating or depressurization, i.e., an adsorption-regeneration cycle. A co-electrolysis module 202 (Co-Elec) consists of several co-electrolyzers connected in parallel, each starting and stopping independently. It is used to simultaneously electrolyze carbon dioxide and water to directly obtain syngas composed of carbon monoxide and hydrogen. A Fischer-Tropsch synthesis module 203 (FTS) consists of several microreactors connected in parallel and / or in series, each starting and stopping independently. Each microreactor contains a Fischer-Tropsch synthesis catalyst (such as a cobalt-based catalyst) to convert the syngas into oils and waxes. The microreactor is equipped with microchannels in various configurations, such as serpentine, fishbone, Tesla one-way valve, or combinations thereof. The Fischer-Tropsch synthesis catalyst is coated on the inner wall of the microchannels or loaded onto a honeycomb carrier or a spherical powder carrier with a nanoporous structure and placed within the microchannels. Hydrogen production module 204 (Elec) consists of several electrolyzers (such as pressure-type alkaline electrolyzers (ALK), atmospheric-pressure alkaline electrolyzers, and proton exchange membrane electrolyzers (PEM)) connected in parallel. Each electrolyzer can be started and stopped independently and is used to electrolyze water to generate hydrogen. Hydrorefining module 205 (Hydro+Dist) includes several hydrogenation reactors and a distillation column. The hydrogenation reactors react oil and wax with hydrogen to generate a mixed fuel. The hydrogenation reactors are connected in parallel and / or in series. The distillation column is connected to the hydrogenation reactors and is used to fractionate the mixed fuel into a single fuel (such as gasoline, aviation fuel, or diesel).

[0037] It should be noted that those skilled in the art can fully understand and improve the specific configurations of each module, including air carbon capture, co-electrolysis, Fischer-Tropsch synthesis, water electrolysis for hydrogen production, and hydrorefining, based on existing technology. For example, the process execution unit 200 needs to be equipped with commonly used public equipment such as cooling water, steam, pumps, and compressors; the air carbon capture module 201 needs to be equipped with gas conveying equipment such as fans; and the hydrorefining module 205 needs to include a high-pressure separator and a circulating hydrogen compressor. The innovation of this invention lies mainly in the parallel modular integration and unified independent control of the above-mentioned process modules; therefore, the configurations of these conventional equipment will not be elaborated upon further.

[0038] Correspondingly, the decision control module 400 also controls the start-up and shutdown of parallel devices in each process module according to future power supply conditions, adjusting the actual operating load of each process module to achieve modular operation. Specifically, the air carbon capture module 201, co-electrolysis module 202, Fischer-Tropsch synthesis module 203, and hydrogen production module 204 can all adjust their operating loads through modular operation, while the hydrorefining module 205 generally requires full-load, steady-state operation and cannot be subject to large load adjustments. Specifically, the decision control module 400 also controls the start-up and shutdown of each solid-state collector in the air carbon capture module 201, the adsorption duration and / or desorption duration (i.e., adsorption-regeneration cycle time), the fan operating frequency, and the heating method (such as utilizing multi-source low-carbon heat) according to future power supply conditions, to achieve dynamic matching between carbon dioxide generation rhythm and power output. The decision control module 400 also controls the start-up and shutdown of each co-electrolyzer in the co-electrolyzer module, the feed rate and ratio of carbon dioxide and water, temperature, electrolysis voltage, and current density based on future power supply conditions, achieving dynamic adjustment of the gas production ratio (CO / H2), pressure, and flow rate. The decision control module 400 also controls the start-up and shutdown of each microreactor in the Fischer-Tropsch synthesis module 203, temperature, pressure, and syngas flow rate based on future power supply conditions, achieving a smooth switch from full load to partial load for the Fischer-Tropsch synthesis module 203. Furthermore, the decision control module 400 controls the start-up and shutdown of each electrolyzer in the hydrogen production module 204, pressure, power supply control, and hot water circulation regulation based on future power supply conditions, achieving load adjustment or hydrogen production rate control for the hydrogen production module 204. The decision control module 400 also controls the circulating hydrogen flow rate, oil and wax input flow rate, and hydrogen input flow rate in the hydrogenation reactor of the hydrorefining module 205 based on future power supply conditions, as well as the temperature, pressure, feed flow rate, and reflux ratio in the distillation column. Simultaneously, the distillation column can be set with multiple operating strategies (such as deep cutting, shallow cutting, and energy-saving modes) to quickly respond to market fluctuations. The decision control module has a relatively large adjustment range for flow parameters in each process module, but a relatively smaller adjustment range for temperature and pressure, especially in the Fischer-Tropsch synthesis and hydrorefining modules, where maintaining stable temperature and pressure parameters is crucial.

[0039] Controlling the circulating hydrogen flow rate, oil and wax input flow rate, and hydrogen input flow rate within the hydrorefining module 205's hydroreactor is primarily to prevent a significant reduction in the hydroreactor's load. There are two main methods to achieve this: one is to supplement with fresh oil and wax and circulating hydrogen, which generally requires oil and wax storage tanks and hydrogen storage tanks; the other is to increase the circulating hydrogen flow rate by appropriately increasing the flow rate of the circulating hydrogen compressor, ensuring minimal pressure drop fluctuations and reduced catalyst activity in the hydroreactor.

[0040] Similarly, controlling the temperature, pressure, feed flow rate, and reflux ratio within the distillation column of the hydrorefining module 205 is also to avoid a significant reduction in the column's load. Thermodynamic stability of the column temperature can be achieved through a flexible and adjustable heat source and condensation system, allowing the reboiler and condenser to accurately respond to load changes. Furthermore, during the distillation column installation phase, widely adaptable internal components (such as high-efficiency trays or packing) and a reasonably designed column diameter ratio can be selected. The multi-stage operating strategies of the distillation column (such as deep-cut, shallow-cut, and energy-saving modes) are for oil distillation. Specifically, mixed oils are divided into several major categories, such as gasoline, kerosene, diesel, and heavy oil, and further subdivided into many smaller categories. "Cutting" refers to the process of separating the oil products. Deep-cut refers to refined operation, such as separating gasoline into several grades; shallow-cut involves separating only the major categories without further subdivision; energy-saving mode maintains the distillation column at minimum load, keeping the reboiler and condenser running, using a full reflux mode, and not collecting any product.

[0041] In one embodiment of the present invention, the process execution device 200 further includes an intermediate product storage module 206, which includes a carbon dioxide storage tank, a syngas storage tank, an oil and wax storage tank, and a hydrogen storage tank. The carbon dioxide storage tank is located between the air carbon capture module 201 and the co-electrolysis module 202, and is used to store carbon dioxide. The syngas storage tank is located between the co-electrolysis module 202 and the Fischer-Tropsch synthesis module 203, and is used to store syngas composed of carbon monoxide and hydrogen. The oil and wax storage tank is located between the Fischer-Tropsch synthesis module 203 and the hydrorefining module 205, and is used to store oil and wax. Furthermore, the oil and wax storage tank is equipped with a heating device to maintain the liquid flow of the oil and wax. The hydrogen storage tank is located between the hydrogen production module 204 and the hydrorefining module 205, and is used to store hydrogen. The decision control module 400 also controls the liquid level in the intermediate product storage module 206 and the opening and closing of the inlet and outlet valves, thereby controlling the raw material input flow rate of each process module.

[0042] This invention also proposes a flexible preparation method for sustainable aviation fuel, which is applied to the flexible preparation system for sustainable aviation fuel as described above, and includes the following steps:

[0043] Collect historical weather data of the green power generation location: Collect and store historical weather data of the green power generation location for the past 10-20 years in the system, and collect historical weather data of the local area for the past 5-10 days before forecasting;

[0044] Predict the future power supply of green energy based on historical weather data and weather forecast data for the next 1-7 days in the location of green energy sources;

[0045] Collect process data such as temperature, pressure, liquid level, raw material input flow rate and / or product output flow rate for each process module in the preparation of sustainable aviation fuel;

[0046] The allocation of green electricity in the five process modules of sustainable aviation fuel preparation process—air carbon capture module, co-electrolysis module, Fischer-Tropsch synthesis module, hydrogen production module, and hydrogen refining module—will be adjusted based on future power supply conditions and collected process data.

[0047] Based on the operating load allocated to each process module and the real-time data collected, dynamic collaborative control adjusts the temperature, pressure, and / or raw material input flow rate in each process module, as well as the energy storage module and the corresponding intermediate product storage module.

[0048] One embodiment of the present invention adjusts the allocation of five process modules—air carbon capture, co-electrolysis, Fischer-Tropsch synthesis, hydrogen production, and hydrorefining—in a sustainable aviation fuel production process based on future power supply conditions and collected process data. Specifically, each process module needs to be assigned a priority, and power allocation is based on this priority. Since the hydrorefining module can rely on inventory adjustments within the intermediate product storage module, the air carbon capture, co-electrolysis, and hydrogen production modules have higher priorities than subsequent processes.

[0049] One embodiment of the present invention predicts the future power supply of green energy based on historical weather data of the location of green energy sources and weather forecast data for the next 1-7 days, specifically including:

[0050] AI models are used to identify time-series patterns and fluctuation characteristics of historical green electricity generation output.

[0051] By combining meteorological information and seasonal patterns to predict the future power supply of green electricity, the power generation forecast curves for each time period of the day are obtained.

[0052] The flexible preparation method for sustainable aviation fuel according to one embodiment of the present invention further includes: adjusting the actual operating load of each process module within the safe load range of each process module by controlling the number of devices turned on in each process module according to the future power supply situation.

[0053] In the sustainable aviation fuel production process, the Fischer-Tropsch synthesis module operates at approximately twice the load of the hydrorefining module. The minimum load for the Fischer-Tropsch synthesis module is 40%, while the minimum load for the hydrorefining module is 80%. The output of the Fischer-Tropsch synthesis module at its minimum load matches the amount of feedstock required for the hydrorefining module at its minimum load.

[0054] It should be noted that operating load refers to the percentage of the equipment's actual processing capacity to its designed maximum processing capacity. For example, 100% load = full-load operation, and 50% load = half-load operation.

[0055] The following is a detailed description of the flexible preparation system and method for sustainable aviation fuel of the present invention.

[0056] The flexible SAF (Carbon Atomization) preparation process in this invention is mainly divided into five process segments: Direct Air Carbon Capture (DAC) (Segment 1), Carbon Dioxide Electroreduction (Segment 2), Fischer-Tropsch Synthesis (Segment 3), and Hydrogenation Refining and Distillation Purification (Segment 4), plus an auxiliary process segment: Water Electrolysis for Hydrogen Production (Segment 5). Segments 1, 2, 3, and 5 all adopt a modular operation design. The flexibility of the modular operation equipment is mainly reflected in parallel configuration, unit independence, and easy scalability. Each module, as the smallest functional unit, can be started, stopped, and maintained independently without affecting the continuous operation of the overall system. Through the parallel arrangement of multiple modules, the system can dynamically adjust the number of modules in operation according to changes in external energy or load, achieving flexible switching from low load to full load. The modular design also facilitates on-demand expansion of system capacity to adapt to different scales of application requirements. Furthermore, the decoupling between modules gives the system strong anti-interference and fault isolation capabilities, improving operational safety and stability. This feature enables modular equipment to exhibit excellent flexibility and adaptability in scenarios such as green electricity operation, intermittent operation, or frequent load fluctuations, facilitating efficient and intelligent process control. The following discussion focuses on specific process sections:

[0057] I. In the air carbon capture module

[0058] Solid-state adsorption (SSA) has garnered significant attention in distributed ducting systems (DACs) due to its design, equipment, and operational flexibility, exhibiting strong system adaptability, particularly suitable for intermittent operation under renewable energy supply conditions. SSA typically employs functionalized porous solid materials (such as amino-modified silica gel and porous carbon materials) to adsorb carbon dioxide from the air at room temperature or low to medium temperatures, and utilizes solar energy or waste heat to achieve desorption and regeneration through heating or depressurization. Compared to liquid absorption methods, SSA systems offer faster start-up and shutdown response times, lower thermal inertia, and smaller system inertia, making them easier to coordinate with fluctuating green energy sources such as wind and solar power. In terms of equipment design, SSA systems can adopt a modular parallel structure, with each collector independently controllable, supporting zoned start-up and shutdown and load switching, facilitating flexible scheduling of operating status based on real-time power supply.

[0059] The system flexibility of solid-state DACs also stems from the carbon retention capacity and temporal lag of the adsorbent material: solid adsorbents possess strong CO2 retention capabilities, allowing them to "store carbon" for extended periods without becoming ineffective, thus enabling more flexible desorption arrangements and effectively functioning as carbon dioxide storage tanks. Solid-state adsorption DACs physically separate adsorption and regeneration (desorption) processes, exhibiting significant operational temporal flexibility. When power resources are scarce, the energy-intensive desorption process can be suspended, retaining only the adsorption operation to "store" CO2 in the adsorbent, resuming desorption when power becomes abundant. This lag allows the DAC system to adjust energy consumption over time, effectively adapting to fluctuations in renewable energy. Therefore, the flexibility of solid-state DACs originates from the temporal decoupling of the operating process, the load adjustment capability of the modular structure, the selection space for adsorbent materials, and the programmable control of the process rhythm, providing excellent adaptability to low-carbon capture systems driven by green electricity.

[0060] In terms of operational strategy, the operating rhythm and power output can be dynamically matched by adjusting the adsorption-regeneration cycle time, fan operating frequency, and heating method (such as utilizing multi-source low-carbon heat). Simultaneously, the system can operate at full power when power is sufficient to improve CO2 capture efficiency, and partially shut down or reduce load when power is limited, ensuring overall energy efficiency and economy. Based on its multiple flexible characteristics in design, equipment, and operation, solid adsorption has become one of the most suitable technical paths for green electricity-driven DACs.

[0061] Experiments show that each kilogram of adsorbent can adsorb approximately 0.02-0.05 kilograms of carbon dioxide in a single pass, with an adsorption time of 1-3 hours and a desorption time of 0.2-1 hour. Therefore, the carbon retention capacity of the adsorbent and the lag between adsorption and desorption can be utilized to achieve flexible operation of the DAC (Digital Converter). The DAC trap is designed in sections based on production capacity, with a single trap achieving an industrial-scale production capacity of 100-500 tons of CO2 per year.

[0062] II. In the carbon dioxide electroreduction module

[0063] Carbon dioxide reduction employs a co-electrolysis method, simultaneously electrolyzing CO2 and H2O in an electrolyzer to directly obtain syngas containing CO and H2, providing ideal feedstock for downstream synthesis of sustainable aviation fuel (e-SAF). To adapt to the large fluctuations in renewable energy output, this invention adopts a modular co-electrolyzer design, dividing the electrolysis system into several independent units. Each module can be independently started and stopped, flexibly scheduled according to power supply conditions, thereby achieving rapid response to grid fluctuations and improving system operational flexibility. This structure not only allows for centralized operation to improve syngas generation efficiency when power is abundant and partial shutdown to reduce load when power is insufficient, but it can also work in conjunction with hydrogen electrolysis and energy storage systems to construct an integrated dynamic energy utilization platform encompassing electricity, gas, and carbon.

[0064] Co-electrolyzers also possess flexibility characteristics such as fast load response, large adjustment range, and adjustable product composition: Co-electrolysis syngas production systems exhibit excellent electrical load response capabilities. A single co-electrolyzer can achieve rapid switching from shutdown to full load within milliseconds to seconds, adapting to fluctuating output from renewable energy sources such as wind and solar power. Furthermore, co-electrolyzers maintain high efficiency even under partial load operation, with operating loads stable within a range of 10% to 100%. Its flexibility is not only reflected in rapid response but also in performance stability during significant load adjustments. By controlling the input current density, temperature, and CO2 / H2O feed ratio, co-electrolysis can flexibly adjust the CO / H2 molar ratio in the generated syngas. This characteristic is highly advantageous for downstream processes such as Fischer-Tropsch synthesis, allowing for dynamic matching of syngas composition based on real-time demand, achieving "product flexibility" rather than just "load flexibility." By modularly arranging multiple co-electrolysis units, the system can be started and stopped on demand, intelligently adjusting operating power to achieve optimal matching between grid load regulation, green electricity priority consumption, and gas production plans, making it an important flexible load unit in high-proportion renewable energy scenarios. By precisely controlling the electrolysis current, voltage, and module start-up and shutdown status, dynamic adjustment of the gas production ratio (CO / H2), pressure, and flow rate can be achieved, thereby ensuring the continuous and stable operation of the downstream reaction system under different energy input conditions. This is one of the key technologies for achieving deep coupling between the "electricity-to-fuel" pathway and renewable energy.

[0065] Through testing, the co-electrolyzer was designed in blocks according to production capacity, and the industrial production capacity that a single co-electrolyzer can achieve is 50-300 tons of syngas (carbon-hydrogen ratio = 1:2) / year.

[0066] III. In the Fischer-Tropsch synthesis module

[0067] The Fischer-Tropsch synthesis process is traditionally considered a typical rigid chemical system, characterized by its high dependence on continuous and stable operating conditions. In Fischer-Tropsch synthesis, syngas (CO and H2) must continuously react with a catalyst under high temperature and pressure to produce liquid hydrocarbon products. The process is extremely sensitive to temperature, pressure, and reactant composition; fluctuations in operating conditions can easily lead to catalyst carbon buildup, decreased selectivity, or even reaction stagnation. Specifically, as a strongly exothermic reaction process with high temperature control requirements, Fischer-Tropsch synthesis is suitable for concentrated operation during periods of abundant energy supply (such as peak daytime solar power) to produce concentrated oil and wax intermediates. Currently, microreactors, with their high surface area / volume ratio, excellent heat and mass transfer characteristics, rapid response capabilities, and modular integration advantages, provide strong support for constructing Fischer-Tropsch oil and wax preparation systems with flexible operating capabilities. The flexibility of microreactors in Fischer-Tropsch synthesis stems from their small scale, rapid response, precise temperature control, and modular structure. In microreactors, gaseous reactants flow in laminar flow within microchannels, allowing reaction heat to be effectively removed in a very short time, avoiding hotspot problems in traditional reactors and significantly improving reaction stability and safety. Meanwhile, the microreactor's small size and low thermal inertia enable rapid start-up and shutdown, as well as dynamic capacity adjustment, greatly enhancing the system's adaptability to fluctuating power sources such as wind and solar power. Furthermore, the modular design of the microreactor allows for on-demand start-up and shutdown, flexible expansion or reduction of capacity, and stable operation from 20% to 100% load range through parallel or series connection of different units. Combined with advanced flow, temperature, and pressure regulation and control strategies, the microreactor achieves high conversion rates and excellent selectivity at low loads in Fischer-Tropsch synthesis, making it particularly suitable for the continuous production of Fischer-Tropsch oil and wax products. With the deep integration of microreactors with membrane reactors, online analysis, and AI control technologies, the Fischer-Tropsch synthesis system possesses a higher degree of flexible manufacturing capability, providing a practical path for the large-scale application of synthetic fuels driven by renewable energy.

[0068] Microreactors, with their high specific surface area and microchannel structure, enable rapid heat transfer to the cooling medium, quickly stabilizing the reaction temperature and preventing localized overheating. This characteristic allows them to maintain reaction stability even under external heat source fluctuations and frequent start-ups and shutdowns driven by green electricity, providing a fundamental condition for flexible operation. Due to their small size, low thermal inertia, and rapid start-up, microreactors can complete start-up and shutdown in a short time, making them suitable for coupling with renewable energy cyclical operation. Simultaneously, their structure allows for high-frequency load adjustments by regulating reactant flow rates without causing the reaction system to "run away" or become unstable. Microreactors can employ coated or structured catalysts (such as catalytically coated walls or honeycomb structures), with high coupling between the catalyst and the reactor, facilitating rapid attainment of activation temperature and enhancing the integrated response speed of the reactor and catalyst. Compared to traditional catalytic beds, they are more suitable for intermittent, dynamic load operation. In practical applications, such as Fischer-Tropsch synthesis systems, microreactors can achieve smooth switching from full load to partial load through flow rate and heat flux adjustments, as well as modular parallel connection, adapting to real-time changes in renewable energy input and improving the overall flexibility and stability of the system.

[0069] The flexibility of microreactors also allows for staged temperature and pressure control of the catalyst. Taking a high-pressure reactor as an example, since the operating pressures vary, pressure fluctuations within 10 MPa are limited to 70%, while those between 10 and 100 MPa are limited to 85%. Temperature varies depending on the specific reaction; for example, the Fischer-Tropsch reaction operates at 210-250°C, with a minimum holding temperature of 200°C, while the hydrogenation reaction operates at 330-380°C, with a minimum holding temperature of 300°C. Staged temperature and pressure control of the catalyst can prevent catalyst deactivation and reduce material fatigue caused by frequent temperature and pressure changes in the reactor, thus avoiding potential equipment damage.

[0070] Through testing, the Fischer-Tropsch microreactor was designed in blocks according to production capacity, and the industrial production capacity that a single microreactor can achieve is 50-300 tons of Fischer-Tropsch wax per year.

[0071] IV. In the water electrolysis hydrogen production module

[0072] The water electrolysis hydrogen production module possesses excellent flexible operation capabilities, adapting to the fluctuating power supply demands of renewable energy sources, and is a key technological unit for constructing flexible hydrogen energy systems. Compared to traditional chemical processes, the water electrolysis system can start, stop, or adjust the hydrogen production rate within a wide load range. The load range for pressure-type alkaline electrolyzers (ALK) is 40-120%; for atmospheric-pressure alkaline electrolyzers, it is 10-120%; and for proton exchange membrane electrolyzers (PEM), it is 5%-120%. It operates stably within its respective advantageous range and possesses strong load-tracking capabilities.

[0073] The flexibility of the water electrolysis hydrogen production system is mainly reflected in five aspects: rapid start-up and shutdown response (seconds to minutes), wide load adjustment range, and stability under rapid changes in current density. First, it has a wide load adjustment capability, capable of stable operation within a 10% to 100% load range. Second, it has a fast response speed, especially the PEM electrolyzer, which can achieve second-level start-up and shutdown, adapting to fluctuating green electricity from wind and solar power. Third, it supports frequent start-up and shutdown, with minimal impact on equipment during startup and shutdown, resulting in a long service life. Fourth, it adopts a modular design, allowing multiple electrolysis units to be independently controlled and flexibly combined, facilitating dynamic scheduling based on power fluctuations. Fifth, it can decouple hydrogen production and consumption through a hydrogen storage system, further enhancing the overall system's adjustment capability and operational stability.

[0074] Through power control, modular design, and hot water circulation regulation, rapid switching of operating conditions can be achieved, enabling peak shaving or market price response in conjunction with green energy consumption strategies. Furthermore, flexible operation requires the integration of gas purification, pressure regulation, and safety interlocking systems to prevent efficiency decline, uneven electrode aging, or insufficient gas evolution caused by low-load operation. Overall, the combination of modular design and advanced control system makes it a highly adaptable core technology unit in green energy scenarios.

[0075] Through testing, the water electrolysis hydrogen production system was designed in blocks according to production capacity, and the industrial production capacity that a single electrolyzer can achieve is 200-1000 tons of hydrogen per year.

[0076] V. In the hydrogenation refining module

[0077] Since the fourth stage of the process operates using a traditional chemical engineering model, it is safer to control the minimum load of the hydrorefining and distillation modules at 80%.

[0078] Hydrorefining, as a post-processing step, relies on a stable supply of hydrogen and heat input to ensure the full execution of reactions such as hydrocracking and hydroisomerization. These processes are typically designed for full-load, steady-state operation, resulting in complex and lengthy start-up and shutdown processes, a narrow load adjustment range, and a lack of adaptability to fluctuations in feedstock and power supply, making them difficult to integrate with intermittent renewable energy sources. Furthermore, the high-temperature and high-pressure characteristics of the hydrorefining process itself make it unsuitable for applications with significant temperature and pressure fluctuations caused by large load variations, which pose a risk of equipment fatigue and uncontrollable damage.

[0079] In hydrorefining, the amount of recycled hydrogen used is approximately 10% of the Fischer-Tropsch wax mass. As production load decreases, the amount of recycled hydrogen used also decreases. However, to ensure relatively stable load, there are two ways to avoid this decrease: one is to supplement with fresh Fischer-Tropsch wax and recycled hydrogen, which requires increasing the number of Fischer-Tropsch wax and hydrogen storage tanks; the other is to increase the circulation rate of recycled hydrogen by appropriately increasing the flow rate of the recycled hydrogen compressor, ensuring minimal pressure drop fluctuations and reduced catalyst activity in the hydrorefining reactor.

[0080] Oil distillation systems are difficult to adjust drastically due to their high sensitivity to vapor-liquid balance, reflux ratio, and internal temperature distribution. Excessive load can lead to tray drying and decreased separation efficiency, while excessive load can cause flooding and instability. Furthermore, the heat loads of the reboiler and condenser are difficult to synchronize, and the control system struggles to adapt quickly, impacting product quality and operational stability. Therefore, traditional chemical systems have significant limitations in flexibility and adaptability, making them unsuitable for green chemical scenarios dominated by fluctuating energy sources such as wind and solar power. Achieving flexible operation and meeting the requirements of flexible production systems in hydrotreated oil distillation requires coordinated optimization at the design and control levels. Firstly, by selecting versatile internals (such as high-efficiency trays or packing) and a reasonable column diameter ratio, good separation efficiency can be ensured within a load range of 60%–110%. Secondly, a flexible and adjustable heat source and condensation system should be provided to enable the reboiler and condenser to respond precisely to load changes and maintain thermodynamic stability within the column. Third, an intelligent control system is adopted to achieve dynamic and coordinated adjustment of feed flow rate, reflux ratio, tower pressure, and tower temperature, ensuring stable operation and product quality under different working conditions. Fourth, multiple operating strategies (such as deep cutting, shallow cutting, and energy-saving modes) are set according to production plan requirements to quickly respond to market fluctuations. In addition, improving online analysis capabilities and data-driven optimization models helps to quickly stabilize process parameters during frequent switching. Ultimately, this achieves efficient, safe, and economical operation of the oil distillation unit under different feedstocks, product structures, and market loads, supporting a modern flexible production system.

[0081] In this invention, the Fischer-Tropsch oil and wax hydrorefining and distillation module adopts a configuration strategy of "large-scale front-end synthesis and small-scale back-end oil refining." Specifically, the operating load of the Fischer-Tropsch synthesis system is approximately twice that of the oil refining system. Through a rhythmic differential operation mode of "matching the minimum load of 40% at the Fischer-Tropsch synthesis end with the minimum load of 80% at the oil refining end," it effectively adapts to fluctuating power supply conditions, demonstrating strong process flexibility and system coordination. Alternatively, by configuring an intermediate product buffer system (such as oil and wax storage tanks) to absorb fluctuations in upstream products, a "fast production, slow refining" operation mode can be achieved. This operation mode can effectively improve the load utilization rate and catalyst life of the hydrorefining unit, avoid reaction performance fluctuations caused by frequent start-ups and shutdowns, reduce dependence on power supply stability, and enhance the system's ability to withstand fluctuations in green electricity.

[0082] The system and method of this invention will be described in detail below, taking Hami region as an example.

[0083] The wind and solar power settings for Hami region are as follows: 1. Total installed capacity: 200 units (MW), of which wind power accounts for 60 units (30%) and photovoltaic power accounts for 140 units (70%). 2. Typical conditions in Hami area: Sunshine hours are from 7:00 to 19:00 (solar power output), wind speed is stronger from 0:00 to 6:00 and from 18:00 to 24:00 (wind power output), and wind power output is stronger and more stable at night and in the early morning; the peak output of wind and solar power is "misaligned", which is very suitable for wind and solar complementary power.

[0084] Feature output: as shown in Table 1 and Figure 4 As shown, photovoltaic output starts to climb from 7:00, reaches its peak between 12:00 and 14:00, and then drops rapidly after 18:00; wind power output is high at night and low during the day, forming an "arched bottom"; total output curve: with uninterrupted power supply for 24 hours, the peak is 176MW between 12:00 and 14:00, and stabilizes at 42-45MW between 0 and 6.

[0085] Assuming a limit of 100MW and 40MW, green electricity is in a high output state for 9 hours from 8:30 to 17:30, and in a low output state for 15 hours from 17:30 to 8:30 the next day. Therefore, the flexible system designed in this invention reduces the load to 40% of the design load.

[0086] Table 1. Wind and solar power output in Hami region at different times within 24 hours.

[0087] As shown in Table 1 above, the total redundant energy during peak wind and solar power is approximately 500 MW*h, and the total redundant energy during off-peak periods is approximately 200 MW*h. This redundant energy is used in three parts of energy storage: 30% is stored in batteries, another 30% is stored in compressed air, and the remaining 40% is stored in hydrogen (configured with fuel cells for power generation, such as SOFC).

[0088] Taking an annual production of 10,000 tons of sustainable aviation fuel as an example, the Hami region makes full use of its abundant wind and solar power resources, using green electricity as the only energy input method for the SAF production island area.

[0089] Table 2 below shows the production load and energy consumption of each process segment in a continuous 10,000-ton-level SAF. If a flexible approach is adopted, the following strategy is used: Processes one, two, three, and five can achieve 40%-100% capacity; Process four uses a traditional chemical plant, but to ensure safety, it operates continuously with a load reduction limit of 80% of the design load (the reliable lower limit for stable product composition). The overall equipment for processes one, two, three, and five is designed at 1.6 times the benchmark (material quantity for 8000 hours of continuous operation), i.e., 1.6 times the design of a traditional chemical plant for stable continuous operation. It operates at full load for 9 hours and at 40% full load (0.64 times the benchmark value) for 15 hours. The four stages of the process adopt the traditional chemical process, and the overall equipment is set up according to 1.143 times the benchmark, that is, it is designed according to 1.143 times the traditional chemical stable continuous operation device. It is operated at full load within a 9-hour range and at 80% full load (i.e., 0.91 times the benchmark value) within a 15-hour range.

[0090] Table 2. Production Load and Energy Consumption of Each Process Section in a Continuous 10,000-Ton SAF

[0091] The flexible system has a total power output of 98.20MW during periods of abundant wind and solar power output and 42.15MW during periods of scarce output. Taking a green energy base in Hami, Xinjiang, with 200 units as an example, it can stably output 100MW during a 9-hour peak period and 40MW during a 15-hour valley period, with the addition of energy storage methods (as mentioned above, battery energy storage, compressed air energy storage, and hydrogen energy storage). Alternatively, during the 10-16 period of extremely abundant wind and solar power output, the modular equipment can be used to easily assemble on demand and adjust loads, with additional backup equipment in stages one, two, three, and five. The purpose of this additional equipment is to maximize the utilization of redundant wind and solar power.

[0092] Table 3. Material and Energy Consumption Differences for Each Process Section After Adding Redundant Equipment

[0093] As can be seen from Table 3, the energy consumption of the fourth process section increases by 5.15MW when running at full load for 15 hours, reaching 25.71MW, and the total power of the five process sections reaches 47.3MW.

[0094] From the table above, we can conclude that: 1. The selection of process equipment is based on 22.88% of the design baseline (8000 hours of continuous operation), which can be rounded up to 25%. During the 9-hour wind and solar redundancy period, 7157.62 kg of Fischer-Tropsch wax can be produced (within a 24-hour cycle). This extra Fischer-Tropsch wax is converted into SAF oil within 15 hours, resulting in an additional 286 kg of SAF per hour, achieving full-load operation of all four process stages and a production of 1429 kg of SAF per hour (within a 24-hour cycle). 2. Power is increased by 21.69 MW within 9 hours, reaching a total power of 119.89 MW; and by 5.15 MW within 15 hours, reaching a total power of 47.3 MW. 3. The increased power is largely within the redundancy range, and the possibility of a large-scale impact on normal production and daily energy storage is low. It fully meets the requirements of flexible scheduling and continuous product output for the SAF production system.

[0095] After increasing the process equipment by 25% in the above embodiments, there is still some surplus of redundant wind and solar power. This part of the energy can be stored in the form of energy storage (or simply abandoned). If there is sufficient power, the production capacity can be appropriately increased within 15 hours. Intermediate products can be stored in storage tanks in a certain state (such as the pressure required by downstream processes), including high-pressure carbon dioxide storage tanks, high-pressure syngas storage tanks, Fischer-Tropsch oil and wax storage tanks (with heating to maintain liquid flow) and high-pressure hydrogen storage tanks (integrated energy storage and hydrogen storage), etc.

[0096] It should be noted that the terms "upper", "lower", "left", "right", "inner", "outer", etc., indicate the orientation or positional relationship based on the orientation or positional relationship shown in the accompanying drawings. Such expressions are only for the purpose of making the description of the present invention simpler and more convenient, and do not indicate or imply that the component referred to must have a specific orientation or be constructed and operated in a specific orientation.

[0097] In addition, unless otherwise explicitly specified and limited, terms such as “connection” and “setup” should be interpreted broadly in this application. For example, “connection” can be a fixed connection, a detachable connection, or an integral connection; it can be a mechanical connection or an electrical connection; it can be a direct connection or an indirect connection through an intermediate medium; it can also be a connection between the internal components of two elements. Those skilled in the art can understand the specific meaning of the above terms in this application according to the specific circumstances.

[0098] Although the methods described above are illustrated and depicted as a series of actions for the sake of simplicity, it should be understood and appreciated that these methods are not limited by the order of the actions, as some actions may occur in a different order and / or concurrently with other actions from the illustrations and descriptions herein or not illustrated and described herein but which may be understood by those skilled in the art, according to one or more embodiments.

[0099] The constructions and arrangements of this application shown in several different exemplary embodiments are merely illustrative. Although only a few embodiments are described in detail in this disclosure, those who consult this disclosure will readily understand that many modifications are possible (e.g., changes in size, structure, shape, and proportions, as well as parameter values, installation arrangements, use of materials, orientation, etc.) without substantially departing from the novel teachings and advantages of the subject matter described in this application. For example, an element shown as integrally formed may be composed of multiple parts or elements, the position of the elements may be inverted or otherwise changed, and the nature or number or position of discrete elements may be altered or changed. Therefore, all such modifications are intended to be included within the scope of this invention. The order or sequence of any process or method steps may be changed or rearranged according to alternative embodiments. In the claims, any "device plus function" clause is intended to cover the structure described herein that performs the function, and not only structurally equivalent but also equivalent in structure. Various corresponding modifications and variations can be made by those skilled in the art according to this invention without departing from the spirit and essence of the invention, but such corresponding modifications and variations should fall within the protection scope of this invention.

Claims

1. A flexible preparation system for sustainable aviation fuel, characterized in that, include: Green power module, used to output fluctuating green electricity; The process execution unit, connected to the green power supply module, includes five process modules: an air carbon capture module, a co-electrolysis module, a Fischer-Tropsch synthesis module, a hydrogen production module, and a hydrorefining module. The air carbon capture module captures carbon dioxide from the air and consists of several solid collectors connected in parallel, each of which can be started and stopped independently. The co-electrolysis module, connected to the air carbon capture module, consists of several co-electrolyzers connected in parallel, each of which can be started and stopped independently. It is used to electrolyze carbon dioxide and water to produce syngas containing carbon monoxide and hydrogen. The Fischer-Tropsch synthesis module, connected to the co-electrolysis module, consists of several microreactors connected in parallel and / or in series, each of which can be started and stopped independently. Each microreactor contains a Fischer-Tropsch synthesis catalyst to convert syngas into oil and wax. The hydrogen production module consists of several electrolyzers connected in parallel, each of which can be started and stopped independently. It is used to electrolyze water to produce hydrogen. The hydrorefining module, connected to the Fischer-Tropsch synthesis module and the hydrogen production module, is used to convert oil and wax into aviation fuel through a catalytic hydrogenation reaction. The data acquisition module is used to collect the temperature, pressure, liquid level, raw material input flow rate and / or product output flow rate of each process module in the process execution device; The decision control module predicts the future power supply of green energy based on historical weather data and future weather forecast data of the green energy location, and adjusts the power distribution in each process module according to the future power supply. It also regulates the temperature, pressure and / or raw material input flow in each process module, and regulates the actual operating load of each process module within a set range by controlling the start and stop of the parallel components in each process module.

2. The flexible preparation system for sustainable aviation fuel according to claim 1, characterized in that, All the solid traps adsorb carbon dioxide from the air using porous solid adsorption materials. The hydrorefining module includes several hydrorefining reactors and a distillation column. The hydrorefining reactors are used to react oil and wax with hydrogen to generate a mixed fuel. The hydrorefining reactors are connected in parallel and / or in series. The distillation column is connected to the hydrorefining reactors and is used to fractionate the mixed fuel into a single fuel.

3. The flexible preparation system for sustainable aviation fuel according to claim 2, characterized in that, The decision control module also controls the start-up and shutdown, adsorption duration and / or desorption duration of each solid collector in the air carbon capture module, the start-up and shutdown of each co-electrolyzer in the co-electrolyzer module, the feed rate and temperature of carbon dioxide and water, the start-up and shutdown, temperature, pressure and syngas flow rate of each microreactor in the Fischer-Tropsch synthesis module, the start-up and shutdown and pressure of each electrolyzer in the hydrogen production module, the circulation volume of circulating hydrogen, the input flow rate of oil and wax and the input flow rate of hydrogen in the hydrorefining reactor, and the temperature, pressure and feed flow rate in the distillation column, based on future power supply conditions.

4. The flexible preparation system for sustainable aviation fuel according to claim 2, characterized in that, The microreactor is provided with serpentine, fishbone, and / or Tesla one-way valve-shaped microchannels. The Fischer-Tropsch synthesis catalyst is coated on the inner wall of the microchannel or disposed in the microchannel by being loaded on a honeycomb support or a spherical powder support with a nanoporous structure.

5. The flexible preparation system for sustainable aviation fuel according to claim 2, characterized in that, The process execution device also includes an intermediate product storage module, which includes a carbon dioxide storage tank, a syngas storage tank, an oil and wax storage tank, and a hydrogen storage tank. The carbon dioxide storage tank is located between the air carbon capture module and the co-electrolysis module and is used to store carbon dioxide; The syngas storage tank is located between the co-electrolysis module and the Fischer-Tropsch synthesis module and is used to store syngas composed of carbon monoxide and hydrogen. The oil and wax storage tank is located between the Fischer-Tropsch synthesis module and the hydrorefining module and is used to store oil and wax. The hydrogen storage tank is located between the hydrogen production module and the hydrogen refining module and is used to store hydrogen. The decision control module also controls the liquid level in the intermediate product storage module tank and the opening and closing of the inlet and outlet valves.

6. The flexible preparation system for sustainable aviation fuel according to claim 2, characterized in that, It also includes an energy storage device, which is connected to the green power module and is used to store green electricity. The energy storage device is in the form of battery energy storage, compressed air energy storage and / or hydrogen energy storage.

7. A flexible preparation method for sustainable aviation fuel, characterized in that, The method, applied to the flexible preparation system for sustainable aviation fuel as described in any one of claims 1-6, includes the following steps: Collect historical weather data for the locations of green electricity sources; Predict the future power supply of green energy based on historical weather data and future weather forecast data of the locations where green energy is located; Collect temperature, pressure, liquid level, raw material input flow rate and / or product output flow rate of each process module in the sustainable aviation fuel preparation process; The allocation of green electricity in the five process modules of sustainable aviation fuel preparation process—air carbon capture module, co-electrolysis module, Fischer-Tropsch synthesis module, hydrogen production module, and hydrogen refining module—will be adjusted based on future power supply conditions and collected process data. Control and regulate the temperature, pressure, and / or raw material input flow rate in each process module.

8. The flexible preparation method for sustainable aviation fuel according to claim 7, characterized in that, The prediction of future power supply from green energy sources based on historical weather data and future weather forecasts for the locations of green energy sources specifically includes: AI models are used to identify time-series patterns and fluctuation characteristics of historical green electricity generation output. By combining meteorological information and seasonal patterns to predict the future power supply of green electricity, the power generation forecast curves for each time period of the day are obtained.

9. The flexible preparation method for sustainable aviation fuel according to claim 7, characterized in that, Also includes: Based on future power supply conditions, the actual operating load of each process module is adjusted within the safe load range by controlling the number of devices activated in each process module of the sustainable aviation fuel preparation process.

10. The flexible preparation method for sustainable aviation fuel according to claim 9, characterized in that, In the process of sustainable aviation fuel production, the operating load of the Fischer-Tropsch synthesis module is twice that of the hydrorefining module; The minimum load for the Fischer-Tropsch synthesis module is 40%, and the minimum load for the hydrorefining module is 80%. The output of the Fischer-Tropsch synthesis module at its minimum load is matched with the amount of feed required for the hydrorefining module at its minimum load.

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