Modular design system for coupling blue hydrogen production with carbon capture and working method of modular design system

Abstract

The invention discloses a modular design system for coupling blue hydrogen production with carbon capture and a working method of the modular design system. High-temperature waste heat generated by the gasification module is used for regeneration of an absorbent in the carbon capture module, so that energy consumption is reduced; synthesis gas directly enters the purification module, tail gas of the purification module enters the carbon capture module, and intermediate cooling and reheating processes are reduced; the intelligent control system dispatches the operation states of all the modules in a unified mode, and optimal matching of energy and materials is achieved.

Description

TECHNICAL FIELD

[0001] The present application relates to the technical field of blue hydrogen production and carbon capture, and particularly relates to a modular design system for blue hydrogen production coupled with carbon capture and a working method thereof. BACKGROUND

[0002] With the increasing demand for clean energy worldwide, hydrogen energy, as an important clean energy, has gradually attracted attention. Blue hydrogen is mainly produced by gasification of fossil fuels, combined with carbon capture and storage technology (CCUS), which effectively reduces carbon emissions.

[0003] However, the existing hydrogen production and carbon capture devices are mostly single and fixed structures, lacking flexible modular design. In addition, the linkage efficiency between hydrogen purification, carbon capture and storage needs to be improved, and the current situation cannot meet the changing industrial demand and scale adjustment.

[0004] Therefore, it is necessary to propose a multifunctional integrated system with modular design, integrated hydrogen production, purification and carbon capture, efficient energy utilization, which can not only improve the overall process efficiency, but also realize scale, resource and customized configuration, which has important practical significance and broad application prospect. SUMMARY

[0005] The present application aims to at least partially solve one of the technical problems in the related art.

[0006] To this end, an embodiment of the present application proposes a modular design system for blue hydrogen production coupled with carbon capture and a working method thereof.

[0007] In a first aspect, the present application proposes a modular design system for blue hydrogen production coupled with carbon capture, comprising: a gasification module, the gasification module comprising a gasifier and a waste heat boiler arranged downstream of the gasifier, a raw material gas and a gasifying agent entering the gasifier to react to produce high-temperature synthesis gas; a purification module, the high-temperature synthesis gas entering the waste heat boiler for waste heat utilization to produce high-pressure saturated steam, and then entering the purification module, and obtaining high-purity hydrogen gas through a pressure swing adsorption process; a carbon capture module, the carbon capture module comprising an absorption tower and a regeneration tower arranged downstream of the absorption tower, tail gas of the purification module entering the absorption tower, a reboiler being arranged at the bottom of the regeneration tower, and the high-pressure saturated steam providing a heat source for the reboiler; a compression and transportation module arranged downstream of the purification module and the carbon capture module, the compression and transportation module comprising a compressor and a storage unit.

[0008] Further, the raw material gas comprises one of natural gas and coal gas.

[0009] Further, the gasification module further comprises a dust filter, a desulfurization tank and a preheater arranged in sequence upstream of the gasification furnace, the raw gas flows through the dust filter, the desulfurization tank and the preheater in sequence and then enters the gasification furnace, and the high-pressure saturated steam provides heat source for the preheater.

[0010] Further, sulfides in the raw gas are removed to below 0.1 ppm in the desulfurization tank by using a desulfurizing agent, and the desulfurizing agent comprises zinc oxide or activated carbon.

[0011] Further, the purification module is a multi-tower pressure swing adsorption system, and the multi-tower pressure swing adsorption system is used to adsorb impurities in the synthesis gas at high pressure and desorb to obtain high-purity hydrogen gas with a purity of above 99.99% by periodic pressure change.

[0012] Further, CO2 in the tail gas of the purification module in the absorption tower is absorbed to obtain a rich liquid, and the rich liquid is heated and desorbed in the regeneration tower to obtain CO2.

[0013] Further, a gas-liquid separation tank is arranged at the top outlet end of the regeneration tower, and the desorbed CO2 is separated by the gas-liquid separation tank to obtain high-purity CO2.

[0014] Further, the high-purity hydrogen gas and the high-purity CO2 are respectively compressed by the compressor and stored in a storage unit for storage or utilization.

[0015] Further, an intelligent control module is further included, and the intelligent control module comprises a sensor and a controller, and remote monitoring is realized by using the sensor and the controller.

[0016] In the second aspect, a working method of the system in the first aspect is provided, and the working method comprises the following steps: (1) The raw gas enters the gasification module to be converted into high-temperature synthesis gas, and the heat of the high-temperature synthesis gas is recovered to generate high-pressure saturated steam; (2) The synthesis gas enters the purification module to generate tail gas and high-purity hydrogen gas; (3) The tail gas enters the carbon capture module to generate high-purity CO2; (4) The high-purity hydrogen gas and the high-purity CO2 are compressed by the compression and transportation module and then stored or utilized.

[0017] Compared with the prior art, the present application has the following beneficial effects: The system of the present application significantly reduces the carbon capture energy consumption through waste heat recovery, realizes energy integration optimization; adopts modular design, supports multiple configurations from small distributed to large centralized; intelligent control operation, realizes unattended operation, remote control, fault diagnosis and early warning; multi-scene applicability, can be used for new construction or low-carbon modification of existing devices; provides clean hydrogen energy while realizing near-zero emission, has carbon trading potential, realizes environmental and economic win-win. BRIEF DESCRIPTION OF DRAWINGS

[0018] The above and / or additional aspects and advantages of the present application will become apparent and more readily appreciated from the following description, taken in conjunction with the following drawings, in which: Figure 1 A schematic diagram of the modular design system for blue hydrogen production coupled with carbon capture of the present application; Figure 2 A schematic diagram of the gasification module of the present application. DETAILED DESCRIPTION

[0019] The embodiments of the present application are described in detail below, examples of which are shown in the accompanying drawings, in which the same or similar reference numerals represent the same or similar elements or elements having the same or similar functions throughout. The embodiments described below by reference to the accompanying drawings are exemplary and are intended to explain the present application, and cannot be understood as a limitation of the present application.

[0020] The modular design system for blue hydrogen production coupled with carbon capture and its working method proposed by the present application are described below in conjunction with the accompanying drawings.

[0021] As shown in Figure 1 , the modular design system for blue hydrogen production coupled with carbon capture of the present application comprises a gasification module, a purification module, a carbon capture module, a compression and transportation module and an intelligent control module.

[0022] The gasification module is used to convert fossil fuels into syngas, while capturing waste heat for use in the carbon capture module and the like in the subsequent system. As shown in Figure 2 , the gasification module comprises a dust removal filter, a desulfurization tank, a preheater, a gasification furnace and a waste heat boiler arranged in sequence from upstream to downstream.

[0023] The dust removal filter, the desulfurization tank and the preheater are used for pretreatment of the raw gas. The raw gas passes through the dust removal filter, the desulfurization tank and the preheater in sequence, uses the dust removal filter to remove solid particulate matter and dust, uses the desulfurizer in the desulfurization tank to remove the content of sulfides (H2S, COS) in the raw gas to below 0.1 ppm, and uses the preheater to exchange heat between the raw gas and the system waste heat, heating the raw gas to the optimal temperature required for the gasification reaction. Among them, the raw gas is natural gas or coal gas, the desulfurizer uses zinc oxide or activated carbon, and when the raw gas is natural gas, the raw gas is heated to 300-400℃.

[0024] The pretreated feed gas and the gasifying agent are mixed and then enter the gasifier, and a high-temperature synthesis gas is generated by non-catalytic partial oxidation at high temperature. The gasifying agent includes oxygen and water vapor, and the feed gas reacts with the gasifying agent in the gasifier to generate the synthesis gas. The high-temperature synthesis gas at the outlet of the gasifier has a temperature of 1200-1400°C and mainly includes H2 and CO. The high-temperature synthesis gas flows out of the gasifier and enters the waste heat boiler to heat the feed water to generate high-pressure saturated steam, thereby recovering the heat of the high-temperature synthesis gas.

[0025] The purification module is arranged downstream of the gasification module, the high-temperature synthesis gas is cooled after waste heat utilization in the waste heat boiler, and the cooled synthesis gas enters the purification module. In the purification module, the impurity gas except hydrogen in the synthesis gas is removed by a pressure swing adsorption process to obtain high-purity hydrogen.

[0026] The purification module includes a multi-tower pressure swing adsorption (PSA) system, which includes an adsorption tower, a program-controlled valve, a buffer tank and the like. The multi-tower pressure swing adsorption system realizes adsorption and desorption of impurities by periodic pressure change: adsorption of CO2, CO, CH4 and the like in the synthesis gas at high pressure, and desorption at low pressure, thereby obtaining high-purity hydrogen with a purity of more than 99.99%. Among them, the adsorption at high pressure refers to adsorption at a pressure of 2.0-3.0 MPa, and the desorption at low pressure refers to desorption at a pressure of 0.1-0.3 MPa.

[0027] The carbon capture module captures CO2 by using a chemical absorption method, mainly including an absorption tower and a regeneration tower arranged downstream of the absorption tower. The absorption tower is a tower filled with regular packing or random packing, the top of the absorption tower is provided with a lean liquid distributor and a demister, and the bottom is provided with a rich liquid collecting device. The tail gas in the purification module, i.e. the desorbed impurity gas, enters the absorption tower from the bottom of the tower, and the absorbent (lean liquid) sprays downward from the top of the tower. The tail gas and the absorbent amine liquid are countercurrently contacted in the tower, the active components (such as 20%-30% MEA aqueous solution) in the amine liquid reversibly react with CO2 in the tail gas to form weakly combined compounds, thereby capturing CO2 from the gas phase into the liquid phase, and the purified gas (mainly nitrogen, unreacted CH4, H2 and the like) is discharged from the top of the tower, and the rich amine liquid (rich liquid) that has absorbed CO2 flows out from the bottom of the tower.

[0028] A reboiler is arranged at the bottom of the regeneration tower, and high-pressure saturated steam provides heat source for the reboiler. A gas-liquid separation tank is arranged at the outlet end of the top of the regeneration tower. In the working process, the rich amine liquid first passes through the lean-rich liquid heat exchanger to exchange heat with the hot lean amine liquid flowing out from the bottom of the regeneration tower, recover heat and be preheated, and the preheated rich amine liquid enters the upper part of the regeneration tower.

[0029] At the bottom of the regeneration tower, the reboiler uses high-pressure saturated steam from the waste heat boiler of the gasification module as a heat source to heat the amine liquid at the bottom of the tower to boiling (approximately 100~120°C). The heat released by the steam heating breaks the chemical bonds between CO2 and the amine liquid in the rich amine liquid, desorbing high-purity CO2 gas.

[0030] The desorbed CO2 gas and water vapor mixture rises to the top of the tower, where it is separated by a gas-liquid separator. The water vapor is condensed and refluxed, while high-purity CO2 (purity >99%) is discharged from the top of the tower and enters the compression and transport module. The regenerated lean amine solution flows out from the bottom of the tower, is further cooled by a lean-rich liquid heat exchanger and an amine liquid cooler, and is then pumped back to the top of the absorption tower for reuse.

[0031] The high-grade waste heat generated during the gasification process of this invention is recovered and used to drive the energy-intensive regeneration process in carbon capture, which greatly reduces the external energy consumption of the entire system and improves the overall energy efficiency and economy.

[0032] The compression and transport module is located downstream of the purification and carbon capture modules. This module includes a compressor and a storage unit. High-purity hydrogen (pure blue hydrogen) from the purification unit outlet is compressed to 20-70 MPa by the compressor and then stored in the storage unit for easy storage or transport. Hydrogen is used as fuel in power generation, transportation, and as a chemical feedstock, or it can be directly injected into hydrogen pipeline networks.

[0033] High-purity CO2 is compressed into liquid CO2 by a compressor and then stored in a storage unit for preservation or utilization. CO2 is used in oil recovery, food industry, urea production, carbonated beverages and other fields. The preserved CO2 is transported to geological storage sites (such as depleted oil and gas fields, seabed, brackish water layers, etc.) through pipelines or tank trucks.

[0034] The intelligent control module includes sensors and controllers, enabling remote monitoring. The sensors include thermocouples, pressure transmitters, gas chromatographs, flow meters, and level sensors. Monitored parameters include temperature, pressure, flow rate, gas composition, liquid level, and power consumption. Automatic adjustment is achieved using a PLC or DCS system, supporting remote monitoring and big data analysis.

[0035] The system of this invention significantly reduces carbon capture energy consumption through waste heat recovery, achieving energy integration and optimization; it adopts a modular design, supporting various configurations from small-scale distributed to large-scale centralized systems; it features intelligent control and operation, enabling unattended operation, remote control, fault diagnosis and early warning; it is applicable to multiple scenarios, and can be used for new construction or low-carbon retrofitting of existing facilities; it provides clean hydrogen energy while achieving near-zero emissions, possesses carbon trading potential, and achieves a win-win situation for both the environment and the economy.

[0036] Each functional unit in this invention is an independent module that can be manufactured, transported, and installed independently. The modules are connected through standardized interfaces, supporting rapid assembly and disassembly. The number of modules can be flexibly increased or decreased according to production capacity requirements (such as increasing the number of gasifiers or adsorption towers). It supports remote monitoring and intelligent control, enabling "plug-and-play" expansion.

[0037] In this invention, the high-temperature waste heat generated by the gasification module is used to regenerate the absorbent in the carbon capture module, reducing energy consumption; the syngas directly enters the purification module, and the tail gas from the purification module enters the carbon capture module, reducing intermediate cooling and reheating processes; the intelligent control system uniformly schedules the operating status of each module to achieve optimal matching of energy and materials.

[0038] This invention achieves flexible adjustment and convenient expansion of the process through modular design, meeting the needs of different scales and application scenarios. It is applicable to centralized hydrogen supply and carbon capture in industrial parks, clean energy transformation of fossil energy bases, distributed energy supply on offshore platforms or in remote areas, blue hydrogen preparation and carbon capture for hydrogen fuel cell vehicle refueling stations, and low-carbon transformation of high-energy-consuming industries such as chemical and metallurgical industries.

[0039] The working method of the modular design system for blue hydrogen production coupled with carbon capture of the present invention includes the following steps: (1) The raw material gas enters the gasification module and is converted into high-temperature synthesis gas. The heat of the high-temperature synthesis gas is recovered to generate high-pressure saturated steam. (2) Syngas enters the purification module to produce exhaust gas and high-purity hydrogen; (3) The exhaust gas enters the carbon capture module to generate high-purity CO2; (4) High-purity hydrogen and high-purity CO2 are compressed and stored or utilized after being transported by the compression module.

[0040] Specifically, the feed gas reacts with a gasifying agent in a gasifier to generate syngas. The high-temperature syngas flows out of the gasifier and enters a waste heat boiler to heat feedwater, producing high-pressure saturated steam, thus recovering the heat from the high-temperature syngas. The cooled syngas then enters a purification module. A multi-tower pressure swing adsorption (PSA) system uses periodic pressure changes to achieve impurity adsorption and desorption: under high pressure, impurities such as CO2, CO, and CH4 in the syngas are adsorbed, and under low pressure, they are desorbed, resulting in high-purity hydrogen with a purity of over 99.99%. The high-purity hydrogen (pure blue hydrogen) is compressed to 20-70 MPa by a compressor and then stored in a storage unit for easy storage or transportation.

[0041] The impurity exhaust gas desorbed from the purification module enters the absorption tower from the bottom, while the absorbent (lean solution) is sprayed down from the top. The exhaust gas and the absorbent amine solution come into countercurrent contact within the tower. The active components in the amine solution (such as a 20%–30% MEA aqueous solution) undergo a reversible chemical reaction with the CO2 in the exhaust gas, forming weakly bonded compounds. This captures CO2 from the gas phase into the liquid phase, forming a rich amine solution. In the regeneration tower, heating the rich amine solution breaks the chemical bonds between CO2 and the amine, desorbing high-purity CO2 gas. The desorbed CO2 gas mixed with water vapor rises to the top of the tower, where it is separated in a gas-liquid separator. The water vapor is condensed and refluxed, while the high-purity CO2 (purity >99%) is discharged from the top. The high-purity CO2 is then compressed into liquid CO2 by a compressor and stored in a storage unit for preservation or utilization.

[0042] In the description of this specification, the references to terms such as "one embodiment," "some embodiments," "example," "specific example," or "some examples," etc., indicate that a specific feature, structure, material, or characteristic described in connection with that embodiment or example is included in at least one embodiment or example of the present invention. In this specification, the illustrative expressions of the above terms may refer to different embodiments or examples. Furthermore, the specific features, structures, materials, or characteristics described may be combined in any suitable manner in one or more embodiments or examples. Moreover, without contradiction, those skilled in the art can combine and integrate the different embodiments or examples described in this specification, as well as the features of different embodiments or examples.

[0043] Furthermore, the terms "first" and "second" are used for descriptive purposes only and should not be construed as indicating or implying relative importance or implicitly specifying the number of technical features indicated. Thus, a feature defined as "first" or "second" may explicitly or implicitly include at least one of that feature. In the description of this invention, "a plurality of" means at least two, such as two, three, etc., unless otherwise explicitly specified.

[0044] Although embodiments of the invention have been shown and described, those skilled in the art will understand that various changes, modifications, substitutions and alterations can be made to these embodiments without departing from the principles and spirit of the invention, the scope of which is defined by the claims and their equivalents.

Claims

1. A modular design system for blue hydrogen production coupled with carbon capture, characterized in that, include: The gasification module includes a gasifier and a waste heat boiler located downstream of the gasifier. Raw material gas and gasifying agent enter the gasifier and react to produce high-temperature syngas. The high-temperature syngas enters the waste heat boiler to generate high-pressure saturated steam, which then enters the purification module and obtains high-purity hydrogen through a pressure swing adsorption process. A carbon capture module includes an absorption tower and a regeneration tower located downstream of the absorption tower. The exhaust gas from the purification module enters the absorption tower. A reboiler is installed at the bottom of the regeneration tower, and the high-pressure saturated steam provides a heat source for the reboiler. A compression transport module is located downstream of the purification module and the carbon capture module, and the compression transport module includes a compressor and a storage unit.

2. The system as described in claim 1, characterized in that, The feedstock gas includes either natural gas or coal gas.

3. The system as described in claim 1, characterized in that, The gasification module also includes a dust filter, a desulfurization tank and a preheater arranged sequentially upstream of the gasifier. The raw gas flows sequentially through the dust filter, the desulfurization tank and the preheater before entering the gasifier. The high-pressure saturated steam provides a heat source for the preheater.

4. The system as described in claim 3, characterized in that, In the desulfurization tank, a desulfurizing agent is used to remove sulfides from the raw gas to below 0.1 ppm. The desulfurizing agent includes zinc oxide or activated carbon.

5. The system as described in claim 1, characterized in that, The purification module is a multi-tower pressure swing adsorption system. The multi-tower pressure swing adsorption system adsorbs impurities in the syngas under high pressure through periodic pressure changes, and desorbs them under low pressure to obtain high-purity hydrogen with a purity of over 99.99%.

6. The system as described in claim 1, characterized in that, In the absorption tower, CO2 in the exhaust gas of the purification module is absorbed to obtain a rich liquid, which is then heated and desorbed in the regeneration tower to obtain CO2.

7. The system as described in claim 6, characterized in that, A gas-liquid separator is installed at the top outlet of the regeneration tower, and the desorbed CO2 is separated into high-purity CO2 by the gas-liquid separator.

8. The system as described in claim 7, characterized in that, The high-purity hydrogen and the high-purity CO2 are compressed by the compressor and then stored in the storage unit for preservation or utilization.

9. The system as described in claim 1, characterized in that, It also includes an intelligent control module, which includes sensors and a controller, and uses the sensors and the controller to achieve remote monitoring.

10. A working method for a modular design system for blue hydrogen production coupled with carbon capture, characterized in that, The system according to any one of claims 1 to 9 comprises the following steps: (1) The raw material gas enters the gasification module and is converted into high-temperature synthesis gas. The heat of the high-temperature synthesis gas is recovered to generate high-pressure saturated steam. (2) Syngas enters the purification module to produce exhaust gas and high-purity hydrogen; (3) The exhaust gas enters the carbon capture module to generate high-purity CO2; (4) High-purity hydrogen and high-purity CO2 are compressed and stored or utilized after being transported by the compression module.

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