Co-production of hydrogen, carbon, electricity and concrete and carbon dioxide capture

Abstract

The hydrocarbon feed stream is exposed to heat in the absence of oxygen to convert the hydrocarbon feed stream into a solid stream and a gas stream. The gas stream is separated into an off-gas stream and hydrogen. The carbon is separated from the solids stream as a carbon stream. The water stream is electrolyzed to produce an oxygen stream and hydrogen. The oxygen and a portion of the carbon are combined to produce electrical energy and a carbon dioxide stream. At least a portion of the carbon stream, cement, and water are mixed to form a concrete mixture. The concrete mixture can be used to produce premixed concrete and precast concrete. The carbon dioxide used to cure the concrete may be derived from a carbon dioxide stream generated by power generation.

Description

Priority Claim

[0001] This application claims priority to U.S. Patent Application No. 18 / 077,643, filed on December 8, 2022, the entire content of which is incorporated herein by reference. Technical Field

[0002] This disclosure relates to the co-production of hydrogen, carbon, and electricity for concrete production. Background Art

[0003] Carbon is an element abundant in the earth's crust. The abundance of carbon, its diversity in the composition of organic compounds, and its ability to form polymers at the temperatures commonly encountered on earth make this element a common element of all known life. The atoms of carbon can be bonded together in various ways, resulting in various allotropes of carbon. Some examples of allotropes of carbon include graphite, diamond, amorphous carbon, carbon nanotubes, carbon fibers, and fullerenes. The physical properties of carbon vary widely based on the allotropic form. Thus, carbon is widely used in a variety of markets on a commercial scale or near commercial scale.

[0004] Hydrogen is the lightest element. Under standard conditions, hydrogen gas is a diatomic molecule and is colorless, odorless, tasteless, non-toxic, and flammable. Hydrogen is the most abundant chemical substance in the universe. Most of the hydrogen on earth exists in molecular form, such as in water and in organic compounds (such as hydrocarbons). Some examples of the use of hydrogen include fossil fuel processing (e.g., hydrocracking) and ammonia production.

[0005] To reduce carbon emissions, there is increasing global interest in the conversion of energy from fossil fuels to renewable and sustainable energy. Some examples of carbon reduction pathways in the conversion of energy to renewable energy include improving energy efficiency, producing and / or using low-carbon fuels, and carbon capture and storage (CCS). Summary of the Invention

[0006] The present disclosure describes technologies related to the co-production of hydrogen, carbon, electricity, and concrete, along with sequestration-ready carbon dioxide. Some aspects of the described subject matter can be implemented as a method. A hydrocarbon feed stream is exposed to heat in the absence of oxygen to convert the hydrocarbon feed stream into a solid stream and a gas stream. The hydrocarbon feed stream contains hydrocarbons. The solid stream contains carbon. The gas stream contains hydrogen. The gas stream is separated into an exhaust stream and a first hydrogen stream. The first hydrogen stream contains at least a portion of the hydrogen from the gas stream. Carbon is separated from the solid stream to produce a carbon stream. Water is electrolyzed to produce an oxygen stream and a second hydrogen stream. The water stream contains water. The oxygen stream contains oxygen. The second hydrogen stream contains hydrogen. At least a portion of the oxygen in the oxygen stream and a first portion of the carbon in the carbon stream are combined to produce an electric current and a carbon dioxide stream. The carbon dioxide stream contains carbon dioxide. A first portion of the electric current produced is used to electrolyze the water stream. A second portion of the carbon stream, a cement stream, and water are combined to form a concrete mixture. The cement stream contains cement. In some embodiments, aggregate is mixed into the concrete mixture. A second portion of the electric current produced is used to pressurize a first portion of the carbon dioxide stream to form a pressurized carbon dioxide stream. The pressurized carbon dioxide stream is in a liquefied or supercritical state. In some embodiments, the pressurized carbon dioxide stream is in a liquefied state. In some embodiments, the pressurized carbon dioxide stream is in a supercritical state. The pressurized carbon dioxide stream is discharged. A first portion of the concrete mixture is discharged as a ready-mix concrete stream. A second portion of the concrete mixture is cured using a second portion of the carbon dioxide stream to produce a precast concrete stream. In some embodiments, at least a portion of the electric current produced is used on-site or off-site for another process that may require heat and / or electricity.

[0007] This aspect and other aspects can include one or more of the following features. The hydrocarbon feed stream can include one or more C1-C22 alkanes, one or more C1-C22 alkenes, or any combination thereof. The hydrocarbon feed stream can include hydrogen. For example, oxygen and carbon can be combined by a direct carbon fuel cell (DCFC) that includes a solid oxide. Oxygen and carbon can be combined by a direct carbon fuel cell operating at a working temperature in the range of about 550 degrees Celsius (°C) to about 900 °C. Heat can be transferred from the gas stream to the buffer fluid by a first waste heat recovery heat exchanger. Before exposing the hydrocarbon feed stream to heat in the absence of oxygen, heat can be transferred from the buffer fluid to the hydrocarbon feed stream by a second waste heat recovery heat exchanger. The heat transferred from the gas stream to the buffer stream can be used to generate electricity by a Rankine cycle. Generating electricity by a Rankine cycle can include: transferring heat from the buffer fluid to a working fluid in a boiler to vaporize the working fluid into a vaporized working fluid. Generating electricity by a Rankine cycle can include: flowing the vaporized working fluid through a turbine and expanding it to generate electricity. Generating electricity by a Rankine cycle can include: condensing the vaporized working fluid into a condensed working fluid. Generating electricity by a Rankine cycle can include: recycling the condensed working fluid to the boiler. Heat can be transferred from the carbon dioxide stream to the buffer fluid by a first waste heat recovery heat exchanger. Before exposing the hydrocarbon feed stream to heat in the absence of oxygen, heat can be transferred from the buffer fluid to the hydrocarbon feed stream by a second waste heat recovery heat exchanger. After curing a second portion of the concrete mixture to produce a precast concrete stream, the remaining portion of the carbon dioxide stream can be flowed to a ready-mix concrete production unit, for example, to facilitate the formation of the concrete mixture. The carbon dioxide stream generated by the direct carbon fuel cell and the carbon dioxide formed by smelting alumina can be isolated in a subterranean formation such that the carbon dioxide stream and the carbon dioxide are not released into the atmosphere.

[0008] Some aspects of the described subject matter can be implemented as a system. The system includes: a hydrocarbon feed stream, a pyrolysis chamber, a gas separation unit, a carbon separation unit, a water stream, an electrolysis unit, a power generation unit, a cement stream, a ready-mixed concrete production unit, and a precast concrete production unit. The hydrocarbon feed stream contains hydrocarbons. The pyrolysis chamber is configured to receive the hydrocarbon feed stream and expose the hydrocarbon feed stream to heat in the absence of oxygen to convert the hydrocarbon feed stream into a solid stream and a gas stream. The solid stream contains carbon. The gas stream contains hydrogen. The gas separation unit is configured to receive the gas stream from the pyrolysis chamber and separate hydrogen from the gas stream to produce a waste gas stream and a first hydrogen stream. The first hydrogen stream contains at least a portion of the hydrogen from the gas stream. The carbon separation unit is configured to receive the solid stream from the pyrolysis chamber and separate carbon from the solid stream to produce a carbon stream. The water stream contains water. The electrolysis unit is configured to receive the water stream and electrical energy. The electrolysis unit is configured to electrolyze the water stream using the electrical energy to produce an oxygen stream and a second hydrogen stream. The oxygen stream contains oxygen. The second hydrogen stream contains hydrogen. The power generation unit is configured to receive at least a portion of the oxygen stream from the electrolysis unit and a first portion of the carbon stream from the carbon separation unit. The power generation unit includes, for example, a direct carbon fuel cell. The direct carbon fuel cell is configured to combine the oxygen from that portion of the oxygen stream and the carbon from that portion of the carbon stream to produce electrical energy and a carbon dioxide stream. The carbon dioxide stream contains carbon dioxide. A first portion of the electrical energy generated by the power generation unit is provided to the electrolysis unit to electrolyze the water stream. The cement stream contains cement. The ready-mixed concrete production unit is configured to receive the cement stream and a second portion of the carbon stream. The ready-mixed concrete production unit is configured to mix the cement stream, the second portion of the carbon stream, and water to form a concrete mixture. In some embodiments, aggregate is mixed into the concrete mixture. The ready-mixed concrete production unit is configured to receive a first portion of the carbon dioxide stream from the power generation unit and a second portion of the electrical energy generated by the power generation unit. The ready-mixed concrete production unit is configured to pressurize the first portion of the carbon dioxide stream using the second portion of the electrical energy generated by the power generation unit to form a pressurized carbon dioxide stream. The pressurized carbon dioxide stream is in a liquefied or supercritical state. The ready-mixed concrete production unit is configured to discharge the pressurized carbon dioxide stream. The ready-mixed concrete production unit is configured to discharge a first portion of the concrete mixture as a ready-mixed concrete stream. The precast concrete production unit is configured to receive a second portion of the concrete mixture from the ready-mixed concrete production unit and a second portion of the carbon dioxide stream from the power generation unit. The precast concrete production unit is configured to cure the second portion of the concrete mixture using the second portion of the carbon dioxide stream to produce a precast concrete stream.

[0009] This aspect and other aspects can include one or more of the following features. The hydrocarbon feed stream can include one or more C1-C22 alkanes, one or more C1-C22 alkenes, or any combination thereof. The hydrocarbon feed stream can include hydrogen. The direct carbon fuel cell can include a solid oxide electrolyte configured to operate at a temperature in the range of about 550°C to about 900°C. The system can include a first waste heat recovery heat exchanger. The first waste heat recovery heat exchanger can be in fluid communication with the gas stream exiting the pyrolysis chamber. The first waste heat recovery heat exchanger can be in fluid communication with a buffer fluid. The first waste heat recovery heat exchanger can be configured to transfer heat from the gas stream to the buffer fluid. The system can include a second waste heat recovery heat exchanger. The second waste heat recovery heat exchanger can be in fluid communication with the hydrocarbon feed stream entering the pyrolysis chamber. The second waste heat recovery heat exchanger can be in fluid communication with the buffer fluid. The second waste heat recovery heat exchanger can be configured to transfer heat from the buffer fluid to the hydrocarbon feed stream before the hydrocarbon feed stream enters the pyrolysis chamber. The system can include a Rankine cycle configured to generate electricity using the heat transferred from the gas stream to the buffer fluid. The Rankine cycle can include a boiler configured to receive a working fluid and the buffer fluid. The boiler can be configured to transfer heat from the buffer fluid to the working fluid to vaporize the working fluid into a vaporized working fluid. The Rankine cycle can include a turbine configured to receive the vaporized working fluid and generate electricity as the vaporized working fluid flows through the turbine and expands. The Rankine cycle can include a condenser configured to receive the vaporized working fluid and condense the vaporized working fluid into a condensed working fluid. The Rankine cycle can include a pump configured to circulate the condensed working fluid to the boiler. The system can include a first waste heat recovery heat exchanger. The first waste heat recovery heat exchanger can be in fluid communication with the carbon dioxide stream exiting the power generation unit. The first waste heat recovery heat exchanger can be in fluid communication with the buffer fluid. The first waste heat recovery heat exchanger can be configured to transfer heat from the carbon dioxide stream to the buffer fluid. The system can include a second waste heat recovery heat exchanger. The second waste heat recovery heat exchanger can be in fluid communication with the hydrocarbon feed stream entering the pyrolysis chamber. The second waste heat recovery heat exchanger can be in fluid communication with the buffer fluid. The second waste heat recovery heat exchanger can be configured to transfer heat from the buffer fluid to the hydrocarbon feed stream before the hydrocarbon feed stream enters the pyrolysis chamber. After curing a second portion of the concrete mixture to produce a precast concrete stream, the precast concrete production unit can be configured to direct the remaining portion of the carbon dioxide stream to a ready-mix concrete production unit. The pyrolysis chamber can include a catalyst. The catalyst can include at least one of activated carbon, carbon black, cobalt, iron, copper, or nickel.

[0010] Details of one or more embodiments of the subject matter of this disclosure are set forth in the accompanying drawings and the description below. Other features, aspects, and advantages of the subject matter will become apparent from the description, the drawings, and the claims. BRIEF DESCRIPTION OF THE DRAWINGS

[0011] Figure 1A It is a schematic diagram of an exemplary system for the co-production of hydrogen, carbon, electricity, and concrete.

[0012] Figure 1B It can be in Figure 1A A schematic diagram of an exemplary pyrolysis chamber that can be implemented in the system.

[0013] Figure 1C It is Figure 1A A schematic diagram of an example of components that can be included in the gas separation unit of the system.

[0014] Figure 1D It is Figure 1A A schematic diagram of an example of components that can be included in the carbon separation unit of the system.

[0015] Figure 1E It can be in Figure 1A A schematic diagram of an exemplary electrolysis unit that can be implemented in the system.

[0016] Figure 1F It can be in Figure 1A A schematic diagram of an exemplary direct carbon fuel cell (DCFC) that can be implemented in the system.

[0017] Figure 1G It is a schematic diagram of an exemplary system for the co-production of hydrogen, carbon, electricity, and concrete that implements waste heat recovery.

[0018] Figure 1H It is a schematic diagram of an exemplary system for the co-production of hydrogen, carbon, electricity, and concrete that implements waste heat recovery.

[0019] Figure 2 It is a schematic diagram of an exemplary Rankine cycle for generating electricity using heat.

[0020] Figure 3 It is a flowchart of an exemplary method for the co-production of hydrogen, carbon, electricity, and concrete. Detailed implementation

[0021] The present disclosure describes a system for the co-production of hydrogen, oxygen, carbon, carbon dioxide, electricity, and concrete. The three main feeds to the system include a hydrocarbon stream, a water stream, and cement. In some embodiments, renewable electricity and / or electricity from the grid is used as needed. The hydrocarbon stream is pyrolyzed to produce solid carbon and hydrogen. The water stream is split by electrolysis to produce oxygen and hydrogen. Electricity can be generated by: (i) burning carbon (e.g., from the pyrolysis of the hydrocarbon stream) in the presence of oxygen (from the electrolysis of the water stream) to produce heat, which can be used to generate steam for a steam turbine, (ii) using a direct carbon fuel cell (DCFC) to combine carbon (from the pyrolysis of the hydrocarbon stream) and oxygen (from the electrolysis of the water stream), or both (i) and (ii). Cement, along with at least a portion of the carbon and electricity, is used to produce concrete and other solid-carbon-based products. In some embodiments, waste heat recovery is implemented for process integration and efficiency optimization. At least a portion of the carbon dioxide produced by the system is captured and used to cure precast concrete and / or ready-mix concrete.

[0022] The subject matter described in the present disclosure can be implemented in specific embodiments to achieve one or more of the following advantages. Carbon dioxide that may be produced as a by-product can be sequestered and / or used in other industrial processes rather than released into the atmosphere. The system is flexible because it can receive various feedstocks, such as conventional hydrocarbons (e.g., natural gas, crude oil, and / or their derivatives), biogas, bio-liquid fuels, or oil waste. The system described herein can be used to utilize the excess solid carbon product obtained from pyrolysis, which may otherwise be difficult to place in the carbon market, and at the same time address the intermittency issue of renewable energy. For example, a portion of the carbon produced by the system can be used as an energy storage medium, while another portion of the carbon produced by the system can be sold in the market as a feedstock for other industrial processes. For example, the carbon produced by the system can be used to form carbon black, synthetic graphite, carbon filaments / fibers, and / or carbon nanostructures (such as carbon nanotubes or carbon nanofibers). For example, at least a portion of the carbon produced by the system can be used for electricity generation. At least a portion of the carbon dioxide produced by the system is used for the production of concrete. Any remaining portion of the carbon dioxide produced by the system is ready for sequestration as it is ready for transportation (e.g., through a pipeline) to be sequestered in subsurface regions of the Earth rather than released into the atmosphere and contributing to carbon emissions.

[0023] Figure 1ASchematic diagram of an exemplary system 100 for the co-production of hydrogen, carbon, and electricity for concrete production. System 100 includes a hydrocarbon feed stream 101. The hydrocarbon feed stream 101 contains hydrocarbons (e.g., alkanes, alkenes, alkynes, cyclic hydrocarbons, aromatic hydrocarbons, and / or non-aromatic hydrocarbons). In some embodiments, the hydrocarbon feed stream 101 contains a variety of hydrocarbons selected from C1-C22 alkanes (i.e., alkanes having a carbon atom number in the range of 1 to 22) and / or C1-C22 alkenes (i.e., alkenes having a carbon atom number in the range of 1 to 22). In some embodiments, the hydrocarbon feed stream 101 further contains components other than one or more hydrocarbons, such as hydrogen. However, the hydrocarbon feed stream 101 does not contain oxygen-containing components. System 100 includes a water stream 103 containing water (i.e., H2O).

[0024] System 100 includes a pyrolysis chamber 110, a gas separation unit 120, a carbon separation unit 130, an electrolysis unit 140, a power generation unit 150, a ready-mixed concrete production unit 170A, and a precast concrete production unit 170B. The pyrolysis chamber 110 is configured to receive the hydrocarbon feed stream 101. The pyrolysis chamber 110 is configured to expose the hydrocarbon feed stream 101 to heat in the absence of oxygen to convert the hydrocarbon feed stream 101 into a solid stream 105 and a gas stream 107. In some embodiments, depending on the composition of the hydrocarbon feed stream 101, the pyrolysis chamber 110 may also produce a liquid (e.g., bio-oil) that exits the pyrolysis chamber 110 together with the solid stream 105. The solid stream 105 contains carbon. The gas stream 107 contains hydrogen. In some embodiments, the gas stream 107 contains carbon (e.g., small particles entrained in the gas stream 107), unreacted hydrocarbons from the hydrocarbon feed stream 101, or both. In some embodiments, the pyrolysis chamber 110 is configured to pyrolyze the hydrocarbon feed stream 101 without using a catalyst (non-catalytic pyrolysis). In some embodiments, the pyrolysis chamber 110 is configured to pyrolyze the hydrocarbon feed stream 101 using a catalyst (catalytic pyrolysis).

[0025] The gas separation unit 120 is configured to receive the gas stream 107 from the pyrolysis chamber 110. The gas separation unit 120 is configured to separate hydrogen from the gas stream 107 to produce a waste gas stream 109 and a first hydrogen gas stream 111. The first hydrogen gas stream 111 contains at least a portion of the hydrogen from the gas stream 107. In some embodiments, the first hydrogen gas stream 111 contains substantially all of the hydrogen in the gas stream 107. In some embodiments, the waste gas stream 109 is the remainder of the gas stream 107 other than the first hydrogen gas stream 111. For example, compared to the first hydrogen gas stream 111, the waste gas stream 109 may contain a relatively small portion of the hydrogen from the gas stream 107. In some embodiments, at least a portion of the waste gas stream 109 is recycled back to the pyrolysis chamber 110 because the waste gas stream 109 may contain unconverted hydrocarbons from the hydrocarbon feed stream 101. In some embodiments, at least a portion of the first hydrogen gas stream 111 is stored and / or transported for other industrial processes such as ammonia production, power generation, a feedstock for hydrogen fuel cells, hydrocarbon desulfurization processes, petroleum refining, metal processing (e.g., steelmaking), fertilizer production, and food processing.

[0026] The carbon separation unit 130 is configured to receive the solid stream 105 from the pyrolysis chamber 110. The carbon separation unit 130 is configured to separate carbon from the solid stream 105 to produce a carbon stream 113. For example, in the case where the solid stream 105 contains one or more liquids, the carbon separation unit 130 separates the carbon from the one or more liquids to produce the carbon stream 113. The carbon stream 113 may contain carbon black, charcoal, synthetic graphite, carbon filaments, carbon fibers, carbon nanostructures (such as carbon nanotubes or carbon nanofibers), or any combination thereof. In some embodiments, at least a portion of the carbon stream 113 is stored and / or transported for other industrial processes such as power generation, tire production, battery production, wind turbine blade production, or electronic product production. In some embodiments, at least a portion of the carbon stream 113 is sold to an external market. In some embodiments, the carbon separation unit 130 is configured to process the carbon stream 113. For example, the carbon separation unit 130 may grind, crush, and / or mill the carbon stream 113 before or after separation to adjust the physical properties (such as average particle size) of the carbon stream 113 according to the desired application.

[0027] The electrolysis unit 140 is configured to receive a water stream 103 and electrical energy. The electrolysis unit 140 is configured to electrolyze the water stream 103 using the received electrical energy to generate an oxygen stream 115 and a second hydrogen stream 117. The oxygen stream 115 contains oxygen. At least a portion (e.g., all of the oxygen stream 115) of the oxygen stream 115 is flowed to the power generation unit 150 to generate electricity. In some embodiments, at least a portion of the oxygen stream 115 is stored and / or transported for other industrial processes, such as fuel combustion, power generation, or other industrial processes, e.g., at a remote location where oxygen can be utilized. The second hydrogen stream 117 contains hydrogen. In some embodiments, at least a portion of the second hydrogen stream 117 is stored and / or transported for other industrial processes, such as ammonia production, power generation, a feedstock for a hydrogen fuel cell, a hydrocarbon desulfurization process, petroleum refining, metal processing (e.g., steelmaking), fertilizer production, and food processing. In some embodiments, at least a portion of the first hydrogen stream 111 and at least a portion of the second hydrogen stream 117 are combined, stored, and / or transported for other industrial processes, such as ammonia production, power generation, a feedstock for a hydrogen fuel cell, a hydrocarbon desulfurization process, petroleum refining, metal processing (e.g., steelmaking), fertilizer production, and food processing. The electrolysis unit 140 can be configured to receive electrical energy from various sources. For example, the electrolysis unit 140 can be configured to receive electrical energy from renewable energy sources. For example, the electrolysis unit 140 can be configured to receive electrical energy from the power grid. For example, the electrolysis unit 140 can be configured to receive electrical energy from the power generation unit 150. For example, the electrolysis unit 140 can be configured to receive electrical energy from a Rankine cycle (an example is shown in Figure 2 and described in more detail below). The electrolysis unit 140 can be configured to switch between sources of electrical energy based on the available electrical energy and the electrical energy demand from various sources.

[0028] The power generation unit 150 is configured to receive at least a portion (e.g., most or all) of the oxygen stream 115 from the electrolysis unit 140 and at least a portion of the carbon stream 113 from the carbon separation unit 130. In some embodiments, the power generation unit 150 includes a direct carbon fuel cell (DCFC) 151. The direct carbon fuel cell 151 is configured to combine oxygen in the portion (or all) of the oxygen stream 115 and carbon in the portion (or all) of the carbon stream 113 to generate electrical energy and a carbon dioxide stream 119. The carbon dioxide stream 119 contains carbon dioxide. The carbon dioxide stream 119 produced by the direct carbon fuel cell 151 is a high-purity carbon dioxide stream. For example, the carbon dioxide stream 119 contains at least 99 volume percent (vol%) or at least 99.9 vol% carbon dioxide. For example, the carbon dioxide stream 119 is pure carbon dioxide. The electrical energy generated by the power generation unit 150 can be distributed, for example, by a power distribution unit 160 described in more detail below. At least a portion of the electrical energy generated by the power generation unit 150 is provided to the electrolysis unit 140 to electrolyze the water stream 103. In some embodiments, at least a portion (e.g., most or all) of the carbon dioxide stream 119 is transported (e.g., via a pipeline) and used in one or more industrial processes, and / or sequestered in, for example, subsurface regions of the Earth. The subsurface region can be a formation defining a reservoir within the Earth, but in other cases, the region can be multiple formations, or a portion of a formation. The subsurface region can include, for example, a formation within a reservoir, a portion of a formation, or multiple formations. In some embodiments, the subsurface region includes a subsurface formation of naturally fractured or porous rock. In some embodiments, the region can penetrate other types of formations, including reservoirs that are not naturally fractured. In some embodiments, at least a portion of the carbon dioxide stream 119 is stored and / or transported for other industrial processes, such as cement production. In some embodiments, at least a portion of the carbon dioxide stream 119 is injected into a subsurface formation, for example, to enhance hydrocarbon recovery from the subsurface formation. The carbon dioxide stream 119 is not released into the atmosphere and thus does not contribute to greenhouse gas emissions.

[0029] The power generation unit 150 can include additional and / or alternative components for power generation other than the direct carbon fuel cell 151. In some embodiments, the power generation unit 150 includes a combustion chamber (not shown) in which the carbon (fuel) in the portion (or all) of the carbon stream 113 burns in the presence of the oxygen (oxidizer) in the portion (or all) of the oxygen stream 115. In such an embodiment, heat is generated when the carbon is oxidized to carbon dioxide. The heat from the combustion can be used in a Rankine cycle (e.g., including a turbine) to generate electricity (an example is in Figure 2shown and described in more detail below). For example, heat from combustion can be used by a boiler to generate steam for a turbine or for power generation. For example, waste heat can be recovered and used to heat other process streams in the system (e.g., hydrocarbon feed stream 101) and / or for power generation, such as by Rankine cycle power generation.

[0030] The ready-mix concrete production unit 170A is configured to receive a cement stream 170' and at least a portion of the carbon stream 113 from the carbon separation unit 130. The ready-mix concrete production unit 170A is configured to mix the cement stream 170', the portion of the carbon stream 113, and water (e.g., water stream 103 or a portion of a different water stream) to form a concrete mixture 170". In some embodiments, aggregate (composed of geological materials such as gravel, sand, and crushed rock) is combined with the cement stream 170', the portion of the carbon stream 113, and water to form the concrete mixture 170". In some embodiments, an additive (such as fly ash) is added to the concrete mixture 170". In some embodiments, the concrete mixture 170" contains from about 1 weight percent (wt%) to about 10 wt% of carbon from the carbon stream 113. In some embodiments, the concrete mixture 170" contains more than about 10 wt% of carbon from the carbon stream 113. The carbon content of the concrete mixture 170" can depend, for example, on the amount of nanoparticles present in the carbon stream 113 (derived from the pyrolysis of the hydrocarbon feed stream 101).

[0031] The ready-mix concrete production unit 170A is configured to receive a first portion of the carbon dioxide stream 119 from the power generation unit 150 and at least a portion of the electrical energy generated by the power generation unit 150. The ready-mix concrete production unit 170A is configured to use the portion of the electrical energy generated by the power generation unit 150 to pressurize (e.g., by a compressor) and cool (e.g., by a heat exchanger) the first portion of the carbon dioxide stream 119 to form a pressurized carbon dioxide stream 171. The pressurized carbon dioxide stream 171 is in a liquefied or supercritical state such that the pressurized carbon dioxide stream 171 can be easily transported to a construction site where concrete is needed. The ready-mix concrete production unit 170A is configured to discharge the pressurized carbon dioxide stream 171 and a first portion of the concrete mixture 170" as a ready-mix concrete stream 172. The ready-mix concrete stream 172 and the pressurized carbon dioxide stream 171 can be transported to, for example, a construction site where concrete is needed. At the construction site, the pressurized carbon dioxide stream 171 can be depressurized and used to cure the ready-mix concrete stream 172 to produce concrete. Curing the ready-mix concrete stream 172 with carbon dioxide from the pressurized carbon dioxide stream 171 can mineralize at least a portion of the carbon dioxide.

[0032] The precast concrete production unit 170B is configured to receive a second portion of the concrete mixture 170” from the ready-mixed concrete production unit 170A and at least a portion of the carbon dioxide stream 119 from the power generation unit 150. In some embodiments, the precast concrete production unit 170B is configured to receive at least a portion of the electrical energy generated by the power generation unit 150. The precast concrete production unit 170B is configured to cure the second portion of the concrete mixture 170” using the portion of the carbon dioxide stream 119 to produce a precast concrete stream 174.

[0033] In some embodiments, the precast concrete production unit 170B is configured to receive at least a portion of the cement stream 170’ and a portion of the carbon stream 113 from the carbon separation unit 130. The precast concrete production unit 170B may be configured to mix the portion of the cement stream 170’, the portion of the carbon stream 113, and water (e.g., the water stream 103 or a portion of a different water stream) to form a concrete mixture, which may be the same or similar to the concrete mixture 170” formed in the ready-mixed concrete production unit 170A. In some embodiments, aggregates (composed of geological materials such as gravel, sand, and crushed rock) are also incorporated to form the concrete mixture. The precast concrete production unit 170B may be configured to pour the concrete mixture into a mold to produce precast concrete of a desired geometry. In some embodiments, the mold includes steel reinforcement, which is a steel reinforcement that provides structural strength and / or shape to the final precast concrete product. The precast concrete production unit 170B may cure the concrete mixture using the portion of the carbon dioxide stream 119 and the portion of the electrical energy generated by the power generation unit 150 to produce a precast concrete stream 174.

[0034] In some embodiments, the portion of the carbon dioxide stream 119 from the power generation unit 150 is cooled and mixed with the concrete mixture 170” in a precast mold. For example, the portion of the carbon dioxide stream 119 is cooled to a maximum temperature of about 100 degrees Celsius (°C) or lower. Carbon dioxide can accelerate the concrete curing process. At least a portion of the carbon dioxide may mineralize in the concrete as it cures. After the concrete mixture 170” in the precast concrete production unit 170B has cured to produce the precast concrete stream 174, the remaining portion of the carbon dioxide may be flowed to the ready-mixed concrete production unit 170A. In some embodiments, the ready-mixed concrete production unit 170A and the precast concrete production unit 170B are configured to operate in a series configuration. In some embodiments, the ready-mixed concrete production unit 170A and the precast concrete production unit 170B are configured to operate in a parallel configuration.

[0035] In some embodiments, the system 100 includes a distribution unit 160. The distribution unit 160 can receive electrical energy from various sources. For example, the distribution unit 160 can be connected to a power grid and receive electrical energy from the power grid. For example, the distribution unit 160 can be connected to a renewable energy source (such as wind energy or solar energy) and receive electrical energy from the renewable energy source. For example, the distribution unit 160 can be connected to a power generation unit 150 and receive electrical energy therefrom. For example, the distribution unit 160 can be connected to a Rankine cycle and receive electrical energy from the Rankine cycle (e.g., from a turbine in the Rankine cycle). The distribution unit 160 can distribute electrical energy to various users. For example, the distribution unit 160 can be connected to an electrolysis unit 140 and deliver electrical energy thereto. For example, the distribution unit 160 can be connected to a pyrolysis chamber 110 and deliver electrical energy thereto. For example, the distribution unit 160 can be connected to a power grid and deliver electrical energy to the grid. For example, the power distribution unit 160 is connected to a Rankine cycle and delivers electrical energy to the Rankine cycle (eg, to a pump in the Rankine cycle).

[0036] In some embodiments, at least a portion of the electrical energy generated by the power generation unit 150 is used by another component of the system 100. For example, at least a portion of the electrical energy generated by the power generation unit 150 can be provided to the electrolysis unit 140 to electrolyze the water stream 103. For example, at least a portion of the electrical energy generated by the power generation unit 150 can be used to provide heat and / or electrical energy to the pyrolysis chamber 110 to pyrolyze the hydrocarbon feed stream 101. For example, at least a portion of the electrical energy generated by the power generation unit 150 can be used to pressurize carbon dioxide in the ready-mix concrete production unit 170A to form a pressurized carbon dioxide stream 171. For example, at least a portion of the electrical energy generated by the power generation unit 150 can be used to produce a concrete mixture in the ready-mix concrete production unit 170A (e.g., to produce a ready-mix concrete stream 172). For example, at least a portion of the electrical energy generated by the power generation unit 150 can be used to cure the concrete mixture in the precast concrete production unit 170B to produce a precast concrete stream 174. In some embodiments, at least a portion of the electrical energy generated by the power generation unit 150 is provided to other users. For example, at least a portion of the electrical energy generated by the power generation unit 150 can be used in other industrial processes. For example, at least a portion of the electrical energy generated by the power generation unit 150 can be transmitted to a power grid, where it can be stored and / or distributed to various users off-site.

[0037] Figure 1B is a schematic diagram of an example of a pyrolysis chamber 110. In some embodiments, Figure 1BAs shown, the pyrolysis chamber 110 includes a catalyst 110a. The catalyst 110a may include at least one of activated carbon, carbon black, cobalt, iron, copper, nickel, or an oxide / rare earth metal such as lanthanum oxide or cerium oxide. The operating pressure within the pyrolysis chamber 110 may be substantially atmospheric pressure (about 1 atmosphere). The pyrolysis chamber 110 includes a heater 110b. In the case where the pyrolysis chamber 110 is a plasma pyrolysis reactor, the heater 110b includes electrodes, and an inert gas is supplied to the pyrolysis chamber 110 along with the hydrocarbon feed stream 101. Electrical energy may be supplied to the electrodes of the heater 110b, and the inert gas serves as a working gas to generate a plasma, thereby pyrolyzing the hydrocarbon feed stream 101. In the case where the pyrolysis chamber 110 is a catalytic or non-catalytic reactor, the heater 110b provides indirect heat through a mechanism that generates radiant heat. For example, the heater 110b may be a gas-based burner or an electric heater including a resistor. In the case where the heater 110b includes electrodes (plasma reactor) or a resistor (electric heater), electrical energy is supplied to the heater 110b to generate heat within the pyrolysis chamber 110.

[0038] Figure 1C FIG. is a schematic diagram of an example of components that may be included in the gas separation unit 120. The gas separation unit 120 may include a gravity settling chamber, a cyclone separator, a bag filter chamber filter, a microfilter, a pressure swing adsorption bed, a temperature swing adsorption bed, a dense membrane, or any combination thereof. As previously mentioned, the gas separation unit 120 separates the gas stream 107 into a waste gas stream 109 and a first hydrogen gas stream 111. The first hydrogen gas stream 111 contains at least most of the hydrogen in the gas stream 107, and the waste gas stream 109 contains the remainder of the gas stream 107. Thus, the gas separation unit 120 is mainly used to extract hydrogen from the gas stream 107. One or more pressure swing adsorption beds, one or more temperature swing adsorption beds, one or more dense membranes, or any combination thereof may be used to extract hydrogen from the gas stream 107. In some cases, the gas stream 107 may contain some solid particles (e.g., solid carbon particles entrained in the gas stream 107). In such cases, one or more gravity settling chambers, one or more cyclone separators, one or more bag filter chamber filters, one or more microfilters, or any combination thereof may be used to remove solids from the gas stream 107. The components included in the gas separation unit 120 are configured to operate within the expected operating range (operating pressure and temperature range) of the gas stream 107 plus a design margin (e.g., ±5%, ±10%, ±15%, ±20%, ±25%, or ±30%). In some embodiments, the gas stream 107 is cooled before entering the gas separation unit 120.

[0039] Figure 1CExamples of a gravity settling chamber, a cyclone separator, a bag filter chamber filter, a pair of pressure swing adsorption beds, and a dense membrane are shown. In one or more gravity settling chambers and / or one or more cyclone separators, the outlet velocity of the gas stream 107 can be less than 300 centimeters per second (cm / s). For example, the outlet velocity of the gas stream 107 leaving the gravity settling chamber can be about 275 cm / s, about 250 cm / s, about 225 cm / s, about 200 cm / s, about 175 cm / s, about 150 cm / s, about 125 cm / s, about 100 cm / s, about 90 cm / s, about 80 cm / s, about 70 cm / s, about 60 cm / s, about 50 cm / s, about 40 cm / s, about 30 cm / s, about 20 cm / s, about 10 cm / s, or about 5 cm / s. In some embodiments, the outlet velocity of the gas stream 107 leaving the gravity settling chamber is preferably less than 30 cm / s. In some embodiments, the gravity settling chamber and / or the cyclone separator are configured to remove solid particles having an average or maximum particle size in the range of about 10 micrometers to about 50 micrometers from the gas stream 107. The density of the solid particles can also be a factor in separating the solid particles from the gas stream 107. In the pressure swing adsorption bed, the extraction of hydrogen from the gas stream 107 depends on various factors such as the pressure difference between the bed and the adsorption material. As Figure 1C shown, for the pressure swing adsorption bed, there are at least two containers that swing within a certain pressure range. During the adsorption process, a fluid (e.g., the gas stream 107) flows through the bed in a first direction, and hydrogen is adsorbed onto one or more beds to produce a waste gas stream 109. During the desorption process, the fluid flows through the bed in a second direction, and hydrogen desorbs from one or more beds to produce a first hydrogen stream 111.

[0040] Figure 1D is a schematic diagram of examples of components that can be included in the carbon separation unit 130. The carbon separation unit 130 can include a gravity settling chamber, a cyclone separator, a bag filter chamber filter, a microfilter, a centrifuge, a wet collector, electrostatic separation, acid flux treatment, or any combination thereof. As previously mentioned, the carbon separation unit 130 separates carbon from the solid stream 105 to produce a carbon stream 113. Thus, the carbon separation unit 130 is mainly used to extract carbon from the solid stream 105. The components included in the carbon separation unit 130 are configured to operate at the expected operating range (operating pressure and temperature range) of the solid stream 105 plus a design margin (e.g., ±5%, ±10%, ±15%, ±20%, ±25%, or ±30%).

[0041] Figure 1DExamples of a gravity settling chamber, a cyclone separator, a bag filter, and a centrifuge are shown. In one or more gravity settling chambers and / or one or more cyclone separators, the outlet velocity of the solid stream 105 can be less than 300 centimeters per second (cm / s). For example, the outlet velocity of the solid stream 105 leaving the gravity settling chamber can be about 275 cm / s, about 250 cm / s, about 225 cm / s, about 200 cm / s, about 175 cm / s, about 150 cm / s, about 125 cm / s, about 100 cm / s, about 90 cm / s, about 80 cm / s, about 70 cm / s, about 60 cm / s, about 50 cm / s, about 40 cm / s, about 30 cm / s, about 20 cm / s, about 10 cm / s, or about 5 cm / s. In some embodiments, the outlet velocity of the solid stream 105 leaving the gravity settling chamber is preferably less than 30 cm / s. In some embodiments, the gravity settling chamber and / or the cyclone separator are configured to remove solid particles having an average or maximum particle size in the range of about 10 microns to about 50 microns from the solid stream 105. Smaller particle sizes may be required for sale to external markets because smaller-sized carbon particles can have greater commercial value compared to larger-sized carbon particles. In such cases, the larger-sized carbon particles can be used, for example, for power generation. The density of the solid particles can also be a factor in separating the solid particles from the solid stream 105. In one or more centrifuges, the rotational speed can depend on the desired size of the carbon particles to be removed from the solid stream 105. For example, the rotational speed of one or more centrifuges can be in the range of about 1,500 revolutions per minute (rpm) to about 50,000 rpm. In some cases, the rotational speed of one or more centrifuges can be greater than 50,000 rpm.

[0042] Figure 1E is a schematic diagram of an example of the electrolysis unit 140. Figure 1E The exemplary electrolysis unit 140 shown in is a polymer electrolyte membrane (PEM) electrolysis unit, but different types of electrolysis units, such as an alkaline water electrolysis unit, a solid oxide electrolysis unit, or an anion exchange membrane (AEM) electrolysis unit, can be used alternatively or additionally. The PEM electrolysis unit 140 includes an anode 140a, a cathode 140b, and a proton exchange membrane 140c. The proton exchange membrane 140c is a solid polymer electrolyte membrane that conducts protons from the anode 140a to the cathode 140b while electrically insulating the electrodes (140a, 140b). The half-reaction occurring on the anode 140a side is also referred to as the oxygen evolution reaction (Equation 1).

[0043]

[0044] The half-reaction occurring on the cathode 140b side is also referred to as the hydrogen evolution reaction (Equation 2).

[0045]

[0046] The water stream 103 enters the PEM electrolysis unit 140. The PEM electrolysis unit 140 decomposes water into hydrogen and oxygen. The generated hydrogen and oxygen are separated from each other. For example, the membrane can be permeable to hydrogen so that hydrogen can pass through the membrane and be separated from oxygen while oxygen remains on the opposite side of the membrane. The oxygen stream 115 exits the PEM electrolysis unit 140 from the anode 140a side, and the second hydrogen stream 117 exits the PEM electrolysis unit 140 from the cathode 140b side.

[0047] The open-circuit voltage for operating the electrolysis unit 140 can be in the range of about 1.2 volts (V) to about 2.5 V. In some embodiments, the operating temperature of the PEM electrolysis unit 140 is in the range of about 50 °C to about 80 °C. In some embodiments, the operating pressure of the PEM electrolysis unit 140 is less than about 70 bar. In some embodiments, the current density of the electrical energy supplied to the PEM electrolysis unit 140 is in the range of about 1 ampere per square centimeter (A / cm 2 ) to about 6 A / cm 2 of the range.

[0048] In the case where the electrolysis unit 140 is an alkaline water electrolysis unit, the open-circuit voltage for operating the electrolysis unit 140 can be in the range of about 1.2 V to about 3 V. In some embodiments, the operating temperature of the alkaline water electrolysis unit 140 is in the range of about 70 °C to about 90 °C. In some embodiments, the operating pressure of the alkaline water electrolysis unit 140 is less than about 70 bar. In some embodiments, the current density of the electrical energy supplied to the alkaline water electrolysis unit 140 is in the range of about 0.2 A / cm 2 to about 6 A / cm 2 of the range.

[0049] In the case where the electrolysis unit 140 is a solid oxide electrolysis unit, the open-circuit voltage for operating the electrolysis unit 140 can be in the range of about 1 V to about 1.5 V. In some embodiments, the operating temperature of the solid oxide electrolysis unit 140 is in the range of about 550 °C to about 900 °C, about 700 °C to about 850 °C, or about 750 °C to about 800 °C. In some embodiments, the operating pressure of the solid oxide electrolysis unit 140 is less than about 30 bar. In some embodiments, the current density of the electrical energy supplied to the solid oxide electrolysis unit 140 is in the range of about 0.3 A / cm 2 to about 6 A / cm 2 of the range.

[0050] When the electrolysis unit 140 is an AEM electrolysis unit, the open circuit voltage of the operating electrolysis unit 140 can be in the range of about 1.2 V to about 2 V. In some embodiments, the operating temperature of the AEM electrolysis unit 140 is in the range of about 40°C to about 80°C. In some embodiments, the operating pressure of the AEM electrolysis unit 140 is less than about 70 bar. In some embodiments, the current density of the electrical energy supplied to the AEM electrolysis unit 140 is in the range of about 0.2 A / cm 2 to about 6 A / cm 2 range.

[0051] Figure 1F is a schematic diagram of an example of a direct carbon fuel cell 151. Figure 1F The exemplary direct carbon fuel cell 151 shown in includes a solid oxide electrolyte 152, but alternatively or additionally, different types of electrolytes can be used, such as molten salts (e.g., hydroxide salts), molten carbonates, or molten tin anodes. Oxygen in the oxygen stream 115 flows to the direct carbon fuel cell 151, and carbon in the carbon stream 113 flows to the direct carbon fuel cell 151. The direct carbon fuel cell 151 combines oxygen and carbon to produce carbon dioxide and electrical energy. The carbon dioxide stream 119 flows out of the direct carbon fuel cell 151. In some embodiments, the solid oxide electrolyte 152 is zirconia (ZrO2). In some embodiments, the solid oxide electrolyte 152 is doped with oxides such as yttrium oxide (Y2O3) or scandium(III) oxide (Sc2O3). The solid oxide electrolyte 152 can be configured to combine carbon and oxygen to produce electrical energy and carbon dioxide at an operating temperature in the range of about 550°C to about 1,000°C, about 600°C to about 1,000°C, about 650°C to about 1,000°C, about 700°C to about 1,000°C, about 750°C to about 1,000°C, about 800°C to about 1,000°C, about 850°C to about 1,000°C, about 900°C to about 1,000°C, or about 950°C to about 1,000°C.

[0052] When the direct carbon fuel cell 151 includes a molten salt electrolyte (e.g., potassium hydroxide or sodium hydroxide), the direct carbon fuel cell 151 can be configured to combine carbon and oxygen at an operating temperature in the range of about 500°C to about 600°C to produce electrical energy and carbon dioxide. When the direct carbon fuel cell 151 includes a molten carbonate electrolyte (e.g., containing lithium, sodium, or potassium), the direct carbon fuel cell 151 can be configured to combine carbon and oxygen at an operating temperature in the range of about 600°C to about 900°C to produce electrical energy and carbon dioxide. When the direct carbon fuel cell 151 includes a molten tin anode, the direct carbon fuel cell 151 can be configured to combine carbon and oxygen at a temperature of about 900°C to produce electrical energy and carbon dioxide.

[0053] Figure 1G A schematic diagram of an exemplary system 100G for co-production of hydrogen, carbon, and electricity that implements waste heat recovery. System 100G can be substantially similar to the system 100 shown in Figure 1A and includes substantially the same components as it. System 100G includes a first waste heat recovery heat exchanger 190G and a second waste heat recovery heat exchanger 190G'. The first waste heat recovery heat exchanger 190G is in fluid communication on a first side with at least a portion of the gas stream 107 leaving the pyrolysis chamber 110. The first waste heat recovery heat exchanger 190G is in fluid communication on a second side with a buffer fluid. The first waste heat recovery heat exchanger 190G is configured to transfer heat from the said portion (or all) of the gas stream 107 to the buffer fluid. Thus, the gas stream 107 is cooled by the first waste heat recovery heat exchanger 190G before being processed by the gas separation unit 120. The second waste heat recovery heat exchanger 190G' can be in fluid communication on a first side with at least a portion of the hydrocarbon feed stream 101 entering the pyrolysis chamber 110. The second waste heat recovery heat exchanger 190G' can be in fluid communication on a second side with the buffer fluid. The second waste heat recovery heat exchanger 190G' can be configured to transfer heat from the buffer fluid to the said portion (or all) of the hydrocarbon feed stream 101 before the hydrocarbon feed stream 101 enters the pyrolysis chamber 110. Thus, the first waste heat recovery heat exchanger and the second waste heat recovery heat exchangers 190G, 190G' cooperate to recover heat from the gas stream 107 and utilize the recovered heat to preheat the said portion (or all) of the hydrocarbon feed stream 101 before pyrolyzing the hydrocarbon feed stream 101 in the pyrolysis chamber 110. The buffer fluid is an intermediate fluid that transfers heat from the gas stream 107 to the hydrocarbon feed stream 101. The buffer fluid can be any suitable fluid capable of transferring heat from the gas stream 107 to the hydrocarbon feed stream 101. For example, the buffer fluid can be an aqueous fluid or an oil-based fluid (such as a hydrocarbon fluid). For example, the buffer fluid can include supercritical carbon dioxide.

[0054] Figure 1H A schematic diagram of an exemplary system 100H for co-production of hydrogen, carbon, and electricity that implements waste heat recovery. System 100H can be substantially similar to Figure 1AThe system 100 shown is substantially similar and includes substantially the same components. System 100H includes a first waste heat recovery heat exchanger 190H and a second waste heat recovery heat exchanger 190H'. The first waste heat recovery heat exchanger 190H is in fluid communication on a first side with at least a portion of the carbon dioxide stream 119 exiting the power generation unit 150. The first waste heat recovery heat exchanger 190H is in fluid communication on a second side with a buffer fluid. The first waste heat recovery heat exchanger 190H is configured to transfer heat from the portion (or all) of the carbon dioxide stream 119 to the buffer fluid. The second waste heat recovery heat exchanger 190H' may be in fluid communication on a first side with at least a portion of the hydrocarbon feed stream 101 entering the pyrolysis chamber 110. The second waste heat recovery heat exchanger 190H' may be in fluid communication on a second side with the buffer fluid. The second waste heat recovery heat exchanger 190H' may be configured to transfer heat from the buffer fluid to the portion (or all) of the hydrocarbon feed stream 101 before the hydrocarbon feed stream 101 enters the pyrolysis chamber 110. Thus, the first waste heat recovery heat exchanger and the second waste heat recovery heat exchangers 190H, 190H' cooperate to recover heat from the gas stream 107 and use the recovered heat to preheat the portion (or all) of the hydrocarbon feed stream 101 before pyrolyzing the hydrocarbon feed stream 101 in the pyrolysis chamber 110. The buffer fluid is an intermediate fluid that transfers heat from the gas stream 107 to the hydrocarbon feed stream 101. The buffer fluid may be any suitable fluid capable of transferring heat from the gas stream 107 to the hydrocarbon feed stream 101. For example, the buffer fluid may be an aqueous fluid, an oil-based fluid (such as a hydrocarbon fluid), or a supercritical fluid (such as supercritical carbon dioxide). Although Figure 1G and 1H show specific examples where waste heat can be recovered from specific regions within each system, waste heat recovery can be implemented anywhere waste heat is generated.

[0055] Figure 2 is a schematic diagram of an exemplary Rankine cycle 200 for using heat to generate electricity. The cycle 200 includes a boiler 210, a turbine 220, a condenser 230, and a pump 240. The pump 240 circulates a working fluid 202 through the cycle 200. As the working fluid 202 flows through the cycle 200, the working fluid 202 undergoes changes in temperature and pressure. As the working fluid 202 flows through the cycle 200, the changes in temperature and pressure cause the working fluid 202 to undergo a phase change. For clarity, the various states (with different phase compositions) of the working fluid 202 are denoted as 202 followed by a letter (e.g., 202a and 202b). As the working fluid 202 flows through the cycle 200, the overall composition of the working fluid 202 does not change. However, based on the operating conditions, heat, and work (thermodynamics), the individual phases (e.g., the gas phase and the liquid phase) may have different compositions.

[0056] The working fluid 202 enters the boiler 210 in liquid form (202a). The boiler 210 is configured to receive the liquid working fluid 202. The boiler 210 is configured to transfer heat to the working fluid 202 to produce a vaporized working fluid 202b. The vaporized working fluid 202b flows from the boiler 210 to the turbine 220. The turbine 220 is configured to receive the vaporized working fluid 202b. The turbine 220 is configured to generate electricity as the vaporized working fluid 202b flows through and expands within the turbine 220. The vaporized working fluid 202b exiting the turbine 220 has a reduced working pressure compared to the vaporized working fluid 202b entering the turbine 220. The vaporized working fluid 202b flows from the turbine 220 to the condenser 230. The condenser 230 is configured to receive and condense the vaporized working fluid 202b into a condensed working fluid 202a. The condensed working fluid 202a flows from the condenser 230 to the pump 240. The pump 240 is configured to recycle the condensed working fluid 202a back to the boiler 210 to restart the cycle 200.

[0057] The heat used by the boiler 210 to vaporize the working fluid 202 can be provided by various sources. In some embodiments, the boiler 210 receives heat from a buffer fluid (e.g., from the first waste heat recovery heat exchanger 190G or 190H). For example, the boiler 210 can be configured to be in fluid communication with the buffer fluid from the first waste heat recovery heat exchanger 190G on a first side and in fluid communication with the working fluid 202 on a second side. For example, the boiler 210 can be configured to be in fluid communication with the buffer fluid from the first waste heat recovery heat exchanger 190H on a first side and in fluid communication with the working fluid 202 on a second side. In some embodiments, the boiler 210 receives heat from the combustion of a fuel (e.g., from the combustion of at least a portion of the carbon stream 113 in the presence of oxygen from at least a portion of the oxygen stream 115 in the power generation unit 150).

[0058] In some embodiments, at least a portion of the electrical energy generated by the turbine 220 is used by components of the system 100, 100G, or 100H. For example, at least a portion of the electrical energy generated by the turbine 220 can be provided to the electrolysis unit 140 to electrolyze the water stream 103. For example, at least a portion of the electrical energy generated by the turbine 220 can be used to provide heat to the pyrolysis chamber 110 to pyrolyze the hydrocarbon feed stream 101. In some embodiments, at least a portion of the electrical energy generated by the turbine 220 is provided to other users. For example, at least a portion of the electrical energy generated by the turbine 220 can be used in other industrial processes. For example, at least a portion of the electrical energy generated by the turbine 220 can be transmitted to the power grid, where it can be stored and / or distributed remotely to various users. For example, at least a portion of the electrical energy generated by the turbine 220 can be provided to other processes on-site at a facility that is co-located with any one of the systems 100, 100G, or 100H.

[0059] Figure 3It is a flowchart of an exemplary method 300 for the co-production of hydrogen, carbon, electricity, and sequestered carbon dioxide for concrete production. Any of systems 100, 100G, or 100H can be used to implement method 300. A hydrocarbon feed stream, such as hydrocarbon feed stream 101, is flowed to a pyrolysis chamber, such as pyrolysis chamber 110. At block 302, the hydrocarbon feed stream 101 is exposed to heat (e.g., within pyrolysis chamber 110) in the absence of oxygen to convert the hydrocarbon feed stream 101 into a solid stream, such as solid stream 105, and a gas stream, such as gas stream 107. As previously mentioned, the solid stream 105 contains carbon and the gas stream 107 contains hydrogen. The gas stream 107 is flowed from the pyrolysis chamber 110 to a gas separation unit, such as gas separation unit 120. At block 304, the gas stream 107 (e.g., within gas separation unit 120) is separated into a waste gas stream, such as waste gas stream 109, and a first hydrogen gas stream, such as first hydrogen gas stream 111, that contains at least a portion of the hydrogen from the gas stream 107. The solid stream 105 is flowed from the pyrolysis chamber 110 to a carbon separation unit, such as carbon separation unit 130. At block 306, carbon is separated from the solid stream 105 (e.g., within carbon separation unit 130) to produce a carbon stream, such as carbon stream 113. A water stream, such as water stream 103, is flowed to an electrolysis unit, such as electrolysis unit 140. Electrical energy is provided to the electrolysis unit 140. At block 308, the water stream 103 is electrolyzed (e.g., by electrolysis unit 140 in response to receiving electrical energy) to produce an oxygen gas stream, such as oxygen gas stream 115, and a second hydrogen gas stream, such as second hydrogen gas stream 117. At least a portion of the oxygen gas stream 115 is flowed from the electrolysis unit 140 to a power generation unit, such as power generation unit 150. At least a portion of the carbon stream 113 is flowed from the carbon separation unit 130 to the power generation unit 150. As previously mentioned, the power generation unit 150 can include, for example, a direct carbon fuel cell 151. At block 310, the oxygen from the portion (or all) of the oxygen gas stream 115 and the carbon from the portion of the carbon stream 113 are combined (e.g., by direct carbon fuel cell 151) to produce electrical energy and a carbon dioxide stream, such as carbon dioxide stream 119. At least a portion of the electrical energy generated at block 310 is used to electrolyze the water stream 103 (block 308). Thus, at least a portion of the electrical energy used to perform the electrolysis at block 308 (e.g., by electrolysis unit 140) is sourced from at least a portion of the electrical energy generated at block 310. In some embodiments, at least a portion of the electrical energy generated at block 310 is used to pyrolyze the hydrocarbon feed stream 101 (block 302). At block 312, a second portion of the carbon stream 113, a cement stream, such as cement stream 170’, and water are combined (e.g., in a ready-mix production unit 170A) to form a concrete mixture 170”. In some embodiments, the concrete mixture 170” also contains aggregates.At block 314, a second portion of the electrical energy generated (block 310) is used to pressurize a first portion of the carbon dioxide stream 119 to form a pressurized carbon dioxide stream (such as pressurized carbon dioxide stream 171). As previously mentioned, the pressurized carbon dioxide stream 171 is in a liquefied or supercritical state. At block 316, at least a portion of the pressurized carbon dioxide stream 171 and a first portion of the concrete mixture 170” as a ready-mixed concrete stream (such as ready-mixed concrete stream 172) are discharged (e.g., from the ready-mixed production unit 170A). The ready-mixed concrete stream 172 and the pressurized carbon dioxide stream 171 can be transported to a remote location where concrete is needed, and the pressurized carbon dioxide stream 171 can be depressurized and used to cure the ready-mixed concrete, which mineralizes at least a portion of the carbon dioxide. At block 318, a second portion of the carbon dioxide stream 119 and a third portion of the electrical energy generated (block 310) are used to cure the concrete mixture 170” (e.g., in a precast concrete production unit 170B) to produce a precast concrete stream (such as precast concrete stream 174). In some embodiments, after curing a second portion of the concrete mixture 170” to produce the precast concrete stream 174 (block 318), the remaining portion of the carbon dioxide stream 119 is flowed from the precast concrete production unit 170B to the ready-mixed concrete production unit 170A to facilitate the formation of the concrete mixture 170” (block 312). Excess carbon dioxide from this process can be used, for example, in other on-site or off-site industrial applications.

[0060] Although this specification contains many specific implementation details, these should not be construed as limitations on the scope that can be claimed, but rather as descriptions of features specific to particular implementations. Certain features described in this specification in the context of different embodiments can also be implemented in combination in a single embodiment. Conversely, the multiple features described in the context of a single embodiment can also be implemented separately in multiple embodiments, or in any sub-combination. Additionally, although the foregoing features may be described as acting in a particular combination and even initially claimed as such, in some cases, one or more features from the claimed combination can be omitted from the combination, and the claimed combination can relate to a sub-combination or a variant of a sub-combination.

[0061] As used in this disclosure, unless the context clearly indicates otherwise, the terms "a," "an," or "the" are used to include one or more referents. Unless otherwise indicated, the term "or" is used to mean a non-exclusive "or." The expression "at least one of A and B" has the same meaning as "A, B, or A and B." Additionally, it should be understood that phrases or terms employed in this disclosure and not otherwise defined are for descriptive purposes only and not for purposes of limitation. The use of any section headings is intended to aid in reading the document and should not be construed as limiting; information related to a section heading may appear within or outside of that particular section.

[0062] As used in this disclosure, the terms "about" or "approximately" may permit a degree of variability in a value or range, such as within 10%, within 5%, or within 1% of the stated value or the stated limits of a range.

[0063] As used in this disclosure, the term "substantially" means mostly or mainly, such as at least about 50%, 60%, 70%, 80%, 90%, 95%, 96%, 97%, 98%, 99%, 99.5%, 99.9%, 99.99%, or at least about 99.999% or more.

[0064] Values expressed in a range format should be understood in a flexible manner to include not only the values explicitly recited as the limits of the range, but also all individual values or sub-ranges subsumed within that range as if each value and sub-range were explicitly recited. For example, a range of "0.1% to about 5%" or "0.1% to 5%" should be interpreted to include from about 0.1% to about 5%, as well as the individual values (e.g., 1%, 2%, 3%, and 4%) and sub-ranges (e.g., 0.1% to 0.5%, 1.1% to 2.2%, 3.3% to 4.4%) within the indicated range. Unless otherwise indicated, the expression "X to Y" has the same meaning as "about X to about Y." Similarly, unless otherwise indicated, the expression "X, Y, or Z" has the same meaning as "about X, about Y, or about Z."

[0065] Specific embodiments of the subject matter have been described. It will be apparent to those skilled in the art that other embodiments, variations, and permutations of the described embodiments are within the scope of the appended claims. Although operations are depicted or claimed in a particular order in the figures, this should not be construed as requiring such operations to be performed in the particular order shown or in a sequential order, or that all of the operations shown (some operations may be considered optional) be performed to achieve the desired result. In certain instances, multitasking or parallel processing (or a combination of multitasking and parallel processing) may be advantageous and may be carried out as appropriate.

[0066] In addition, the separation or integration of the multiple system modules and components in the previously described embodiments should not be construed as requiring such separation or integration in all embodiments, and it should be understood that the described components and systems can generally be integrated together or packaged into multiple products.

[0067] Accordingly, the previously described exemplary embodiments do not define or constrain the present disclosure. Other changes, substitutions, and variations are possible without departing from the spirit and scope of the present disclosure.

Claims

1. A method, the method comprising: exposing a hydrocarbon feed stream containing hydrocarbons to heat in the absence of oxygen to convert the hydrocarbon feed stream into a solid stream and a gas stream, the solid stream containing carbon and the gas stream containing hydrogen; separating the gas stream into an exhaust gas stream and a first hydrogen stream containing at least a portion of the hydrogen from the gas stream; separating the carbon from the solid stream to produce a carbon stream; electrolyzing a water stream containing water to produce an oxygen stream and a second hydrogen stream, the oxygen stream containing oxygen and the second hydrogen stream containing hydrogen; combining at least a portion of the oxygen in the oxygen stream and a first portion of the carbon stream to produce electrical energy and a carbon dioxide stream containing carbon dioxide, wherein a first portion of the electrical energy produced is used to electrolyze the water stream; combining a second portion of the carbon stream, a cement stream containing cement, and water to form a concrete mixture; pressurizing a first portion of the carbon dioxide stream using a second portion of the electrical energy produced to form a pressurized carbon dioxide stream, the pressurized carbon dioxide stream being in a liquefied or supercritical state; discharging the pressurized carbon dioxide stream and a first portion of the concrete mixture as a ready-mixed concrete stream; and curing a second portion of the concrete mixture using a second portion of the carbon dioxide stream to produce a precast concrete stream.

2. The method according to claim 1, wherein the hydrocarbon feed stream contains one or more C1-C22 alkanes, one or more C1-C22 alkenes, or any combination thereof.

3. The method according to claim 2, wherein the hydrocarbon feed stream contains hydrogen.

4. The method according to claim 3, wherein the oxygen and the carbon are combined by a direct carbon fuel cell containing a solid oxide, and the oxygen and the carbon are combined by the direct carbon fuel cell at an operating temperature in the range of about 550 degrees Celsius (°C) to about 900 °C.

5. The method according to claim 4, the method comprising: Transferring heat from the gas stream to a buffer fluid through a first waste heat recovery heat exchanger.

6. The method according to claim 5, the method comprising: Before exposing the hydrocarbon feed stream to heat in the absence of oxygen, transferring heat from the buffer fluid to the hydrocarbon feed stream through a second waste heat recovery heat exchanger.

7. The method according to claim 1, the method comprising: After curing the second portion of the concrete mixture to produce the precast concrete stream, flowing the remaining portion of the carbon dioxide stream to a ready-mixed concrete production unit.

8. The method according to claim 4, the method comprising: Transferring heat from the carbon dioxide stream to a buffer fluid through a first waste heat recovery heat exchanger.

9. The method according to claim 8, the method comprising: Before exposing the hydrocarbon feed stream to heat in the absence of oxygen, transferring heat from the buffer fluid to the hydrocarbon feed stream through a second waste heat recovery heat exchanger.

10. The method according to claim 4, the method comprising: Isolating the carbon dioxide stream produced by the direct carbon fuel cell in an underground formation such that the carbon dioxide stream is not released into the atmosphere.

11. A system, the system comprising: A hydrocarbon feed stream containing hydrocarbons; A pyrolysis chamber configured to receive the hydrocarbon feed stream and expose the hydrocarbon feed stream to heat in the absence of oxygen to convert the hydrocarbon feed stream into a solid stream containing carbon and a gas stream containing hydrogen; A gas separation unit configured to receive the gas stream from the pyrolysis chamber and separate the hydrogen from the gas stream to produce a waste gas stream and a first hydrogen stream containing at least a portion of the hydrogen from the gas stream; A carbon separation unit configured to receive the solid stream from the pyrolysis chamber and separate the carbon from the solid stream to produce a carbon stream; A water stream containing water; An electrolysis unit configured to receive the water stream and electrical energy, the electrolysis unit being configured to electrolyze the water stream using the electrical energy to produce an oxygen stream containing oxygen and a second hydrogen stream containing hydrogen; A power generation unit configured to receive at least a portion of the oxygen stream from the electrolysis unit and a first portion of the carbon stream from the carbon separation unit, and the power generation unit includes a direct carbon fuel cell configured to combine the oxygen from the portion of the oxygen stream and the carbon from the first portion of the carbon stream to produce electrical energy and a carbon dioxide stream containing carbon dioxide, wherein a first portion of the electrical energy generated by the power generation unit is provided to the electrolysis unit to electrolyze the water stream; A cement stream containing cement; A ready-mixed concrete production unit configured to receive the cement stream and a second portion of the carbon stream, the ready-mixed concrete production unit being configured to mix the cement stream, the second portion of the carbon stream, and water to form a concrete mixture, wherein the ready-mixed concrete production unit is configured to receive a first portion of the carbon dioxide stream from the power generation unit and a second portion of the electrical energy generated by the power generation unit, and the ready-mixed concrete production unit is configured to pressurize the first portion of the carbon dioxide stream using the second portion of the electrical energy generated by the power generation unit to form a pressurized carbon dioxide stream in a liquefied or supercritical state, and the ready-mixed concrete production unit is configured to discharge the pressurized carbon dioxide stream and a first portion of the concrete mixture as a ready-mixed concrete stream; And A precast concrete production unit configured to receive a second portion of the concrete mixture from the ready-mixed concrete production unit and a second portion of the carbon dioxide stream from the power generation unit, the precast concrete production unit being configured to cure the second portion of the concrete mixture using the second portion of the carbon dioxide stream to produce a precast concrete stream.

12. The system according to claim 11, wherein the hydrocarbon feed stream comprises one or more C1-C22 alkanes, one or more C1-C22 alkenes, or any combination thereof.

13. The system according to claim 12, wherein the hydrocarbon feed stream comprises hydrogen.

14. The system according to claim 13, wherein the direct carbon fuel cell includes a solid oxide electrolyte configured to operate at a temperature in the range of about 550 degrees Celsius (°C) to about 900 °C.

15. The system according to claim 14, the system including a first waste heat recovery heat exchanger in fluid communication with the gas stream exiting the pyrolysis chamber and a buffer fluid, the first waste heat recovery heat exchanger configured to transfer heat from the gas stream to the buffer fluid.

16. The system according to claim 15, the system including a second waste heat recovery heat exchanger in fluid communication with the hydrocarbon feed stream entering the pyrolysis chamber and the buffer fluid, the second waste heat recovery heat exchanger configured to transfer heat from the buffer fluid to the hydrocarbon feed stream before the hydrocarbon feed stream enters the pyrolysis chamber.

17. The system according to claim 11, wherein the precast concrete production unit is configured to cause the remaining portion of the carbon dioxide stream to flow to the ready-mixed concrete production unit after curing the second portion of the concrete mixture to produce the precast concrete stream.

18. The system according to claim 14, the system including a first waste heat recovery heat exchanger in fluid communication with the carbon dioxide stream exiting the power generation unit and a buffer fluid, the first waste heat recovery heat exchanger configured to transfer heat from the carbon dioxide stream to the buffer fluid.

19. The system according to claim 18, the system including a second waste heat recovery heat exchanger in fluid communication with the hydrocarbon feed stream entering the pyrolysis chamber and the buffer fluid, the second waste heat recovery heat exchanger configured to transfer heat from the buffer fluid to the hydrocarbon feed stream before the hydrocarbon feed stream enters the pyrolysis chamber.

20. The system according to claim 14, wherein the pyrolysis chamber includes a catalyst comprising at least one of activated carbon, carbon black, cobalt, iron, copper, or nickel.

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