Integrated carbon modified reformer and process

Abstract

The integrated reformer includes an outer chamber, a first inlet, a second inlet, and a cooling unit associated with the outer chamber. The first inlet is configured to obtain a first gas flow into a first space in the outer chamber. The second inlet is configured to obtain a second gas flow into the first space in the outer chamber. The cooling unit is configured to absorb thermal energy from the first gas flow.

Description

[Technical field]

[0001] CROSS-REFERENCE TO RELATED APPLICATIONS This U.S. patent application claims priority to Provisional Patent Application No. 63 / 266,827, filed January 14, 2022. The disclosure of this prior application is considered part of the disclosure of this application and is incorporated by reference in its entirety herein.

[0002] The present disclosure generally relates to an integrated carbon modified reformer and a process that includes a CO2 reduction process. [Background technology]

[0003] Unless otherwise indicated herein, the material described in this specification is not prior art to the claims of this application and is not admitted to be prior art by inclusion in this section.

[0004] Plasma-based dissociation reactions may be used to facilitate carbon-based chemical reactions, which may provide high temperatures and energy to drive carbon-based chemical reactions to completion.

[0005] The subject matter claimed in this disclosure is not limited to implementations that solve any disadvantages or that operate only in environments as described above. Rather, this background is provided only to illustrate one example technology area in which some implementations described in this disclosure may be practiced. Summary of the Invention

[0006] One aspect of the disclosure provides an apparatus (such as an integrated reformer) that includes an outer chamber, a first inlet configured to obtain a first gas flow into a first space in the outer chamber, a second inlet configured to obtain a second gas flow into the first space in the outer chamber, and a cooling unit associated with the outer chamber, the cooling unit configured to absorb thermal energy from the first gas flow.

[0007] Implementations of the present disclosure may include one or more of the following optional features: In some implementations, the cooling unit is disposed adjacent to the first inlet. In some implementations, the cooling unit includes a tube disposed around the outer chamber. In some implementations, the tube includes a coolant inlet configured to receive a coolant, and the tube includes a coolant outlet configured to release the coolant that has absorbed at least a portion of the thermal energy from the first gas stream. In some implementations, the coolant received by the coolant inlet includes H2O in a liquid state, and the coolant from the coolant outlet includes H2O in a gaseous state.

[0008] In some implementations, the apparatus includes a reaction chamber in the outer chamber. In some implementations, the coolant from the coolant outlet, the first gas flow, and the second gas flow are provided to a second space in the reaction chamber. In some implementations, the apparatus includes a catalyst in the reaction chamber. In some implementations, the coolant from the coolant outlet, the first gas flow, and the second gas flow pass through the catalyst. In some implementations, the catalyst includes a porous material. In some implementations, the apparatus includes an outlet configured to release a third gas flow from the reaction chamber. In some implementations, the third gas flow is based on a reaction caused by the first gas flow, the second gas flow, and the coolant from the coolant outlet. In some implementations, the first gas flow includes a first synthesis gas, the second gas flow includes a hydrocarbon fuel (e.g., biogas, natural gas, CH4, or any combination thereof), and the third gas flow includes a third synthesis gas.

[0009] In some implementations, the coolant from the coolant outlet is provided to the first space in the outer chamber. In some implementations, the apparatus includes an outlet and a catalyst between the first inlet and the outlet. In some implementations, the outlet releases a third gas stream based on a reaction caused by the first gas stream, the second gas stream, and the coolant from the coolant outlet. In some implementations, the catalyst includes a porous material. In some implementations, the first gas stream includes a first synthesis gas, the second gas stream includes a hydrocarbon fuel (e.g., biogas, natural gas, CH4, or any combination thereof), and the third gas stream includes a second synthesis gas.

[0010] Another aspect of the disclosure provides a system. The system includes a plasma carbon converter including a plasma reactor and an integrated reformer in fluid communication with the plasma reactor. The integrated reformer includes an outer chamber, a first inlet configured to obtain a first gas flow from the plasma reactor into a first space in the outer chamber, a second inlet configured to obtain a second gas flow into the first space in the outer chamber, and a cooling unit associated with the outer chamber. The cooling unit is configured to absorb thermal energy from the first gas flow.

[0011] Implementations of the present disclosure may include one or more of the following optional features. In some implementations, the cooling unit is disposed adjacent to the first inlet. In some implementations, the cooling unit includes a tube disposed around the outer chamber. In some implementations, the tube includes a coolant inlet configured to receive a coolant, and the tube includes a coolant outlet configured to discharge a coolant that has absorbed thermal energy from the first gas stream. In some implementations, the system includes an outlet configured to discharge a third gas stream from the integrated reformer. In some implementations, the third gas stream is based on a reaction caused by the first gas stream, the second gas stream, and the coolant from the coolant outlet. In some implementations, the system includes a heat utilization unit in fluid communication with the outlet. In some implementations, the heat utilization unit is configured to receive the third gas stream and configured to cool the third gas stream to a predetermined temperature suitable for further or downstream processes (e.g., a water-gas shift process). In some implementations, the predetermined temperature for the downstream water gas shift step is between 300°C and 350°C.

[0012] Example implementations are described and explained with additional specificity and detail through the use of the accompanying drawings. [Brief description of the drawings]

[0013] [Figure 1] FIG. 1 illustrates an example operation of a plasma carbon converter (PCCU) according to certain implementations of the present disclosure. [Diagram 2] FIG. 1 illustrates an exemplary carbon dioxide (CO2) reduction and utilization system according to some implementations of the present disclosure. [Diagram 3] FIG. 2 illustrates another exemplary CO2 reduction and utilization system, according to some implementations of the present disclosure. [Figure 4] FIG. 2 illustrates another exemplary CO2 reduction and utilization system, according to some implementations of the present disclosure. [Figure 5A] 1 is a cross-sectional view of an example integrated reformer according to some implementations of the present disclosure. [Figure 5B] 1 is a cross-sectional view of an example integrated reformer according to some implementations of the present disclosure. [Figure 6A] 2 is a cross-sectional view of another example integrated reformer according to some implementations of the present disclosure. [Figure 6B] 2 is a cross-sectional view of another example integrated reformer according to some implementations of the present disclosure. [Figure 7] 1 is a flowchart of an example method of a plasma carbon converter according to some implementations of the present disclosure. DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS

[0014] Like reference symbols in the various drawings indicate like elements.

[0015] In some implementations, chemical reactions (e.g., exothermic reactions) performed using a plasma carbon converter (PCCU) provide a high temperature reaction environment that promotes or accelerates the completion of the chemical reaction. The present disclosure may relate to, among other things, chemical reactions to remove carbon dioxide (CO2) (e.g., reduce CO2 emissions) and / or generate various product gases, such as hydrogen gas (H2), carbon monoxide (CO), and synthesis gas (e.g., gas containing H2 and CO) using a PCCU.

[0016] In some implementations, the PCCU includes a plasma reactor and an integrated reformer in fluid communication with the plasma reactor. Chemical reactions carried out using the plasma reactor can result in a greater yield of product gas because the plasma reactor provides a greater amount of energy to drive the formation of product gas (e.g., synthesis gas).

[0017] In some implementations, energy (e.g., kinetic energy, thermal energy) generated from the operation of the plasma reactor drives further operation of other processing units and / or chemical reactions. For example, energy from the plasma reactor may be used to drive the operation of an integrated reformer, a heat utilization unit associated with the integrated reformer, and / or other steps of formation, recycle, and separation of various product gases.

[0018] In some implementations, the plasma reactor uses microwave plasma (e.g., by exposing the first input source to a microwave plasma (e.g., atmospheric microwave plasma, high pressure microwave plasma)) to convert the CO2 and CH4 in the first input source to a first syngas. In some implementations, an integrated reformer in fluid communication with the plasma reactor receives the first syngas from the plasma reactor, mixes the first syngas with a hydrocarbon fuel, such as biogas (e.g., cleaned biogas containing CO2 and CH4), CH4, natural gas, or any combination thereof, and uses a steam reforming process to convert the mixture of the first syngas and the hydrocarbon fuel to a second syngas. In some implementations, energy from the plasma reactor is utilized for the steam reforming process to conserve energy. As a result, the integrated reformer uses energy (generated from the chemical reaction in the plasma reactor) to convert the CO2, CH4, H2, CO, and H2O (a mixture of the first synthesizer, hydrocarbon fuel, and steam) in the second input source into a second syngas. Using the plasma reactor and the integrated reformer, the PCCU is able to produce larger amounts of syngas using energy from the plasma reactor (without having an additional energy source for the process including the steam reforming process).

[0019] The present disclosure includes several systems in which various types of equipment (e.g., heat utilization units, water gas shift reactors, amine units, pressure swing adsorption units, compressors, precompressors, air separators, separation units) are deployed along with a PCCU to convert various gases (e.g., biogas, natural gas / methane (e.g., gases including CH), CO, various combinations thereof) into syngas (e.g., the second syngas described above) and transform the syngas into various end products (e.g., syngas with various H2 to CO ratios, H2).

[0020] In some implementations, a heat utilization unit associated with the integrated reformer (or PCCU) is configured to adjust the temperature of the second syngas. For example, the heat utilization unit absorbs thermal energy from the second syngas. As a result, the heat utilization unit cools the second syngas so that it is suitable for subsequent processes performed by various equipment (e.g., water-gas shift reactor, amine unit, pressure swing adsorption unit, compressor). In some implementations, the heat utilization unit uses the thermal energy absorbed from the second syngas to provide a coolant, which may include steam (e.g., water steam, superheated water), to the integrated reformer and / or the water-gas shift reactor. In some implementations, the heat utilization unit heats or preheats the feedstock to the integrated reformer (e.g., hydrocarbon fuel, steam for the steam reforming process). In some implementations, the heat utilization unit provides power to various equipment (e.g., compressor, pre-compressor) by converting the thermal energy from the integrated reformer into electricity using a suitable method (e.g., by generating steam that uses the thermal energy to operate a steam turbine).

[0021] In some implementations, the water gas shift reactor facilitates the formation of H2 by a water gas shift reactor in which carbon monoxide and water react reversibly to form CO2 and H2. For example, the water gas shift reactor converts CO and H2O in the second syngas passing through the water gas shift reactor to H2 and CO2 (e.g., converts CO to H2).

[0022] In some implementations, the amine unit is configured to recover or remove CO2 from a process gas (e.g., a second syngas, a gas containing H2 and CO2 generated by a water-gas shift reactor based on the second syngas) input to the amine unit.

[0023] In some implementations, the pressure swing adsorption unit is configured to recover or remove CO and impurities from a process gas (e.g., a gas containing H and CO generated by a water-gas shift reactor and an amine unit) input to the pressure swing adsorption unit.

[0024] FIG. 1 illustrates an example operation of a PCCU 102 according to an implementation of the present disclosure.

[0025] 1, in some implementations, the PCCU 102 includes a plasma reactor 110 and an integrated reformer 120 in fluid communication with the plasma reactor 110. The fluid communication between the plasma reactor 110 and the integrated reformer 120 serves to maintain a bleed stream 114 (including a first syngas generated or converted by the plasma reactor 110) to the integrated reformer 120.

[0026] As shown, in some implementations, the plasma reactor 110 obtains an input stream 112 of biogas (e.g., a gas comprising CH4 and CO2), carbon dioxide (CO2), oxygen (O2), and natural gas / methane (CH4) along with input energy 113 (e.g., microwave energy) and produces or provides an output stream 114 of carbon dioxide (CO2) gas, steam, and a first syngas (a gas comprising H2 and CO). As a result, a reaction of the input stream 112 with the input energy (microwave energy as discussed above) creates a plasma (e.g., microwave plasma) that converts the input stream 112 into the output stream 114 (comprising the first syngas).

[0027] As shown, in some implementations, the reaction between the input stream 112 and the input energy 113 generates a discharge energy 115 (e.g., kinetic energy, thermal energy) in the plasma reactor 110, which is transferred to the integrated reformer 120 via the discharge stream 114. As a result, the temperature of the discharge stream 114 is high (e.g., above 1500° C. in this example). In some implementations, the reaction between the input stream 112 and the input energy 113 in the plasma reactor 110 generates kinetic energy.

[0028] In some implementations, the biogas, CO2, and natural gas / methane react in response to the energy provided to the plasma reactor 110 to produce a first syngas, steam, and a balance of carbon dioxide as a chemical product. As a result, a significant amount of carbon dioxide contained in the input stream 112 is removed. Additionally, the chemical reaction that produced the first syngas may generate power, releasing the chemical products at high temperatures (e.g., 1,000°C, 1,100°C, 1,200°C, 1,300°C, 1,400°C, 1,500°C, 1,600°C, 1,700°C, 1,800°C, 1,900°C, 2,000°C, etc.). As discussed above, in this example, the first syngas from the plasma reactor 110 has a temperature greater than 1500°C.

[0029] 1, in some implementations, the amount of carbon dioxide contained in the input stream 112 to the plasma reactor 110 exceeds the amount of carbon dioxide contained in the output stream 114. In some implementations, the input energy 113 is less than the output energy 115 provided by the plasma reactor 110 because the chemical reactions effected in the plasma reactor 110 are exothermic reactions that generate thermal energy (e.g., heat) during the reaction process. In some implementations, the energy generated by the chemical reactions and / or the carbon dioxide provided by the chemical reactions in the plasma reactor 110 may be recycled and included as an input to the PCCU 100 (e.g., plasma reactor 110, integrated reformer 120) to facilitate further chemical reactions and / or reduction of carbon dioxide (CO2).

[0030] As shown, in some implementations, the integrated reformer 120 obtains an outlet stream 114 (including CO2 gas, steam, and a first syngas) and mixes the outlet stream 114 with additional hydrocarbon fuel (e.g., biogas, CH4, natural gas) and steam to perform fluid reforming. As a result, the integrated reformer 120 generates a second outlet stream 116 including a second syngas (e.g., a hydrogen-rich syngas). In other words, the integrated reformer 120 converts the CO2, CH4, and H2O in the outlet stream 114 into the second outlet stream 116 including the second syngas.

[0031] 2 illustrates an exemplary carbon dioxide (CO2) reduction and utilization system 200 according to some implementations of the present disclosure. The CO2 reduction and utilization system 200 may include a system for producing hydrogen from biogas / natural gas.

[0032] As shown in FIG. 2, in some implementations, the CO2 reduction and utilization system 200 includes a PCCU 202 (including a plasma reactor 210 and an integrated reformer 220 in fluid communication with the plasma reactor 210), a precompressor 232, a compressor 234, a scrubber 236, an air separator 238, a heat utilization unit 240, a water gas shift reactor 242, an amine unit 244, and a pressure swing adsorption unit 246.

[0033] As shown, in some implementations, the inlet of the precompressor 232 is in fluid communication with a biogas input source. As a result, the precompressor 232 can control the pressure of the biogas steam into the system 200 (e.g., into the scrubber 236 as shown in FIG. 2). In some implementations, the precompressor 232 increases the pressure of the biogas steam into the system 200. For example, the input biogas can be obtained by the precompressor 232 at 0.5 atm, 1 atm, 1.5 atm, 2 atm, or other pressure, and the biogas exiting the precompressor 232 (e.g., the biogas stream into the scrubber 236) can be at a pressure of 2 atm, 3 atm, 5 atm, 10 atm, 20 atm, 100 atm, or other pressure.

[0034] As shown, in some implementations, the outlet of the precompressor 232 is in fluid communication with the inlet of the scrubber 236. As a result, the scrubber 236 receives the biogas (e.g., pressurized biogas) from the precompressor 232. In some implementations, the scrubber 236 removes impurities, contaminants, or harmful components of the biogas received from the precompressor 232. For example, the scrubber 236 may include a dry purification process in which harmful substances (e.g., sulfur oxides, particulate matter, acid gases, etc.) are adsorbed onto a dry reagent contained in the scrubber 236. As another example, the scrubber 236 may include a wet purification process in which a wet material (e.g., water) is sprayed onto the biogas (from the precompressor 232) to separate one or more components from the biogas. As shown, the outlet of the scrubber 236 is in fluid communication with the integrated reformer 220. As a result, a purified biogas (eg, gas containing CH4 and CO2) stream is provided to the integrated reformer 220.

[0035] As shown, in some implementations, the air separator 238 takes the input air stream and separates it into its constituent components, which may primarily include nitrogen gas (N2) and oxygen gas (O2). The air separator 238 may facilitate separation of the components contained in the input air stream by fractionation, pressure swing adsorption, vacuum pressure swing adsorption, membrane separation, or by any other separation method. As shown, in some implementations, the air separator 238 is in fluid communication with the PCCU 202 (e.g., in fluid communication with the plasma reactor 210 of the PCCU 202). As shown, the fluid communication may send the separated air components to the plasma reactor 210 of the PCCU 202.

[0036] In some implementations, the plasma reactor 210 includes a plasma chamber made from quartz or ceramic materials, with one or more waveguides in the plasma chamber configured to facilitate chemical reactions occurring in the plasma chamber. As shown, in some implementations, the plasma reactor 210 is configured to obtain a natural gas (CH4-containing gas) stream from a natural gas input source, separated air components from an air separator 238, and carbon dioxide from an amine unit 244 to affect a chemical reaction between the inlet gas streams, as described in more detail below.

[0037] In some implementations, in the plasma reactor 210, CH4 from the inlet natural gas stream and CO2 from the amine unit 244 are converted to H2 and CO (first syngas) using a microwave plasma (e.g., by exposing the CO2 and CH4 to a microwave plasma). In some implementations, the plasma reactor 210 converts the CO2 and CH4 to H2 and CO instantly without combustion. As a result, the plasma reactor 210 continues to receive CO2 from the amine unit 244 and CH4 from the natural gas input source, so that it can convert the CO2 and CH4 to a first syngas (contained in the first output stream).

[0038] In some implementations, in the plasma reactor 210, a mixture of gases including CO2, CH4, and O2 from the natural gas input source, the amine unit 244, and the air separator 238 is used to generate H2 and CO using a microwave plasma (e.g., by exposing a mixture of CO2, CH4, and O2 to a microwave plasma). In some implementations, the plasma reactor 210 instantly generates H2 and CO (first synthesis gas) using a mixture of gases including CO2, CH4, and O2 without combustion. As a result, the plasma reactor 210 continuously receives CO2, CH4, and O2, so that the mixture of gases including CO2, CH4, and O2 can be used to generate a first synthesis gas (included in the first output stream).

[0039] In some implementations, heat is generated during the syngas conversion process in the plasma reactor 210. The heat (e.g., thermal energy) generated in the plasma reactor 210 increases the temperature of the first effluent stream and the temperature of the first syngas contained in the first effluent stream. For example, the temperature of the first syngas may be between 1500°C and 2500°C. In some implementations, as discussed above, an integrated reformer 220 in fluid communication with the plasma reactor 210 is configured to receive the first effluent stream comprising the first syngas from the plasma reactor 210. As a result, at least a portion of the thermal energy generated in the plasma reactor 210 is transferred to the integrated reformer 220 via the first effluent stream comprising the first syngas (e.g., a syngas having a temperature greater than 1500°C).

[0040] In some implementations, the integrated reformer 220 comprises a separate reactor connected to the plasma reactor 210. Additionally or alternatively, the plasma reactor 210 and the integrated reformer 220 may be a single device, whereby the formation of a syngas (e.g., a second syngas) by the integrated reformer 220 occurs at a plasma reactor / integrated reformer combined unit.

[0041] As shown, in some implementations, the integrated reformer 220 includes a steam methane reforming reactor or any other reactor configured to convert a first syngas (H2 and CO), CO2, CH4, and HO from the first discharge stream of the plasma reactor 210, the purified biogas from the scrubber 236, and steam (e.g., superheated water) from the heat utilization unit 240 into a second syngas (included in the second discharge stream).

[0042] In some implementations, steam to the integrated reformer 220 is provided by a cooling unit 514 / 614 as described in more detail below. In some implementations, the cooling unit 514 / 614 is configured to cool the first discharge stream (including the first syngas) from the plasma reactor 210. In some implementations, the cooling unit 514 / 614 is configured to cool the first syngas to a temperature range (e.g., 700°C to 1000°C) for the steam reforming process. In some implementations, the cooling unit 514 / 614 uses water as a coolant to cool the first discharge stream (including the first syngas) from the plasma reactor 210. The coolant may include water in any form, including steam. In some implementations, the cooling unit 514 / 614 is configured to provide steam, which is the water that is heated in the process of cooling the first discharge stream (including the first syngas) from the plasma reactor 210 to the integrated reformer 220.

[0043] As shown, in some implementations, the integrated reformer 220 is configured to obtain recycle steam from the amine unit 244. In some implementations, the integrated reformer 220 is configured to obtain steam from the heat utilization unit 240, from the cooling unit 514 / 614, and / or from the amine unit 244. As a result, additional reactants are provided to facilitate greater conversion of the first syngas and biogas to one or more product gases (in this example, the second syngas).

[0044] As shown, the integrated reformer 220 is in fluid communication with a heat utilization unit 240 (e.g., a heat exchanger). In some implementations, the fluid communication routes the second effluent stream (including the second syngas) generated by the integrated reformer 220 to the heat utilization unit 240. In some implementations, the heat utilization unit 240 is configured to cool the second effluent stream including the second syngas from the integrated reformer 220 so that the second effluent stream including the second syngas is more suitable for further processing (e.g., a water-gas shift process). In some implementations, the heat utilization unit 240 is configured to cool the second effluent stream including the second syngas to a predetermined temperature or a predetermined temperature range (e.g., 300°C to 350°C for a water-gas shift process). As shown, in some implementations, water is provided to the heat utilization unit 240 as a coolant, process water, or make-up water. When the water cools the second effluent stream comprising the second syngas in the heat utilization unit 240, the water absorbs heat energy from the second effluent stream comprising the second syngas. Thus, the state of the water changes to a gas (e.g., superheated water), which can be provided to the integrated reformer 220 and / or the water-gas shift reactor 242.

[0045] As shown, in some implementations, the thermal utilization unit 240 includes a power generation unit (e.g., a steam turbine). In some implementations, the power generation unit uses the steam generated in the thermal utilization unit 240 to generate power (e.g., generate electricity).

[0046] As discussed above, the heat utilization unit 240 may include a steam generation unit configured to receive an input stream of water (e.g., as a coolant, process water, or make-up water) and a second output stream including the second syngas generated by the integrated reformer 220. The heat utilization unit 240 may use residual heat generated by the plasma reactor 210, which is input to the heat utilization unit 240 by the incoming second output stream (including the second syngas) from the integrated reformer 220, to vaporize or heat the input water, and the generated steam may be sent to the water-gas shift reactor 242. In some implementations, any excess steam from the heat utilization unit 240 is sent to the integrated reformer 220 to facilitate the formation of the second syngas in the integrated reformer 220.

[0047] As shown, in some implementations, the heat utilization unit 240 is in fluid communication with the water-gas shift reactor 242. In some implementations, the fluid communication sends the second effluent stream (including the second synthesis gas) to the water-gas shift reactor 242 after the cooling step in the heat utilization unit 240. In some implementations, the water-gas shift reactor 242 facilitates the formation of H2 by the water-gas shift reactor 242, where carbon monoxide and water react reversibly to form CO2 and H2. For example, the water-gas shift reactor 242 converts CO and H2O in the second effluent stream (including the second synthesis gas) passing through the water-gas shift reactor 242 to a third effluent stream including H2 and CO2 ("product gas" in FIG. 2). As shown, in some implementations, after the water-gas shift step in the water-gas shift reactor 242, the product gas is sent back to the heat utilization unit 240 for further cooling steps. For example, the heat utilization unit 240 cools the product gas from the water-gas shift reactor 242 to a predetermined temperature or to a predetermined temperature range (eg, 40° C. to 50° C.).

[0048] As shown, in some implementations, the heat utilization unit 240 is configured to receive the product gas from the heat utilization unit 240 ("cool" the product gas, including H2, CO2, and unreacted or partially reacted substances) and is in fluid communication with the compressor 234 configured to compress the product gas. As shown, the compressor 234 is in fluid communication with the amine unit 244. In some implementations, the compressor 234 operates based on power (e.g., electricity) generated by the heat utilization unit 240 as discussed above. As a result, the compressor 234 receives the product gas and provides the product gas to the amine unit 244 after compression. For example, the product gas may be obtained by the compressor 234 at a pressure of 0.5 atm, 1 atm, 1.5 atm, 2 atm, or other pressure, and the product gas exiting the compressor 234 may be at a pressure of 2 atm, 3 atm, 5 atm, 10 atm, 20 atm, 100 atm, or other pressure.

[0049] The amine unit 244 may contain an aqueous solution of various amines that react with the product gas exiting the compressor 234 to remove any remaining impurities (e.g., hydrogen sulfide, sulfur oxides, or other harmful substances). Additionally or alternatively, the amines included in the amine unit 244 may facilitate removal of acid gases such as carbon dioxide. In some implementations, the carbon dioxide removed by the amine unit 244 is recycled back to the plasma reactor 210 to facilitate further syngas reactions (to generate the first syngas). As shown, in some implementations, any partially reacted or unreacted gases in the product gas entering the amine unit 244 are drawn back to the integrated reformer 220 in a recycle stream to drive the chemical reactions associated with the formation of the syngas (in this example, the second syngas) and / or hydrogen gas products to a higher degree of completion.

[0050] As shown, in some implementations, the amine unit 244 is in fluid communication with a pressure swing adsorption unit 246 configured to receive product gas from the amine unit 244. In some implementations, the product gas including hydrogen gas from the amine unit 234 and any residual gas are sent to the pressure swing adsorption unit 246 to further separate the resulting gases. In some implementations, for example, the pressure swing adsorption unit 246 includes an adsorbent that separates hydrogen gas from any other gases that entered the pressure swing adsorption unit 246 by capturing compounds that pass through the adsorbent in addition to the hydrogen gas. The gas captured by the adsorbent may be desorbed from the adsorbent by reducing the pressure in the pressure swing adsorption unit 246, and the desorbed gas (e.g., CO) may be recycled to the PCCU 202 (e.g., to the integrated reformer 220) for further reaction. In other words, the amine unit 244 and the pressure swing adsorption unit 246 remove non-hydrogen gases from the product gas including H2 and CO2 from the water-gas shift reactor 242. As a result, the carbon dioxide (CO2) reduction and utilization system 200 can reduce CO2 and generate high purity H2 (eg, 99.95% H2).

[0051] Modifications, additions, or omissions may be made to the carbon dioxide reduction and utilization system 200 without departing from the scope of the present disclosure. For example, the names of the different elements as described are intended to aid in explaining the concepts described herein and are not limiting. For example, in some implementations, the precompressor 232, the scrubber 236, the air separator 238, the PCCU 202 including the plasma reactor 210 and the integrated reformer 220, the heat utilization unit 240, the water gas shift reactor 242, the compressor 234, the amine unit 244, and the pressure swing adsorption unit 246 are depicted in the particular manner described to aid in explaining the concepts described herein, but such depictions are not intended to be limiting. Furthermore, the carbon dioxide reduction and utilization system 200 may include any number of other elements or be implemented within other systems or contexts other than those described.

[0052] 3 illustrates an example carbon dioxide (CO2) reduction and utilization system 300 according to some implementations of the present disclosure. The CO2 reduction and utilization system 300 may include a system for producing syngas from biogas.

[0053] As shown in FIG. 3, in some implementations, the CO2 reduction and utilization system 300 includes a PCCU 302 (including a plasma reactor 310 and an integrated reformer 320 in fluid communication with the plasma reactor 310), a precompressor 332, a compressor 334, a scrubber 336, an air separator 338, a heat utilization unit 340, an amine unit 344, and a separation unit 348.

[0054] As shown, in some implementations, the inlet of the precompressor 332 is in fluid communication with a biogas input source. As a result, the precompressor 332 can control the pressure of the biogas flow into the system 300 (e.g., to the scrubber 336 as shown in FIG. 3). In some implementations, the precompressor 332 increases the pressure of the biogas flow into the system 300. For example, the input biogas can be obtained by the precompressor 332 at a pressure of 0.5 atm, 1 atm, 1.5 atm, 2 atm, or other pressure, and the biogas exiting the precompressor 332 (e.g., the biogas flow to the scrubber 336) can be at a pressure of 2 atm, 3 atm, 5 atm, 10 atm, 20 atm, 100 atm, or other pressure.

[0055] As shown, in some implementations, the outlet of the precompressor 332 is in fluid communication with the inlet of the scrubber 336. As a result, the scrubber 336 receives the biogas (e.g., pressurized biogas) from the precompressor 332. In some implementations, the scrubber 336 removes impurities, contaminants, or harmful components of the biogas received from the precompressor 332. For example, the scrubber 336 may include a dry purification process in which harmful substances (e.g., sulfur oxides, particulate matter, acid gases, etc.) are adsorbed onto a dry reagent contained in the scrubber 336. As another example, the scrubber 336 may include a wet purification process in which a wet material (e.g., water) is sprayed onto the biogas (from the precompressor 332) to separate one or more components from the biogas. As shown, the outlet of the scrubber 336 is in fluid communication with the plasma reactor 310 and the integrated reformer 320. As a result, a stream of purified biogas (eg, a gas containing CH4 and CO2) is provided to the plasma reactor 310 and the integrated reformer 320.

[0056] As shown, in some implementations, the air separator 338 takes the input air stream and separates it into its constituent components, which may primarily include nitrogen gas (N2) and oxygen gas (O2). The air separator 338 may facilitate separation of the components contained in the input air stream by fractionation, pressure swing adsorption, vacuum pressure swing adsorption, membrane separation, or by any other separation method. As shown, in some implementations, the air separator 338 is in fluid communication with the PCCU 302 (e.g., in fluid communication with the plasma reactor 310 of the PCCU 302). As shown, the fluid communication may send the separated air components to the plasma reactor 310 of the PCCU 302.

[0057] In some implementations, the plasma reactor 310 includes a plasma chamber made from quartz or ceramic materials, with one or more waveguides in the plasma chamber configured to facilitate chemical reactions occurring in the plasma chamber. As shown, in some implementations, the plasma reactor 310 is configured to obtain the biogas stream from the scrubber 336, the separated air component from the air separator 338, and affect a chemical reaction between the inlet gas stream.

[0058] In some implementations, in the plasma reactor 310, the CO2 and CH4 in the purified biogas stream from the scrubber 336 are converted to H2 and CO (first syngas) using a microwave plasma (e.g., by exposing the CO2 and CH4 to a microwave plasma). In some implementations, the plasma reactor 310 converts the CO2 and CH4 instantly to H2 and CO without combustion. As a result, the plasma reactor 310 continues to receive purified biogas so that it can convert the CO2 and CH4 to the first syngas (contained in the first effluent stream).

[0059] In some implementations, in the plasma reactor 310, the mixture of gases including CO2, CH4, and O2 from the scrubber 336 and the air separator 338 is used to generate H2 and CO using microwave plasma (e.g., by exposing the mixture of CO2, CH4, and O2 to microwave plasma). In some implementations, the plasma reactor 310 instantly generates H2 and CO (first synthesis gas) using the mixture of gases including CO2, CH4, and O2 without combustion. As a result, the plasma reactor 310 continuously receives CO2, CH4, and O2, so that the mixture of gases including CO2, CH4, and O2 can be used to generate the first synthesis gas (included in the first discharge stream).

[0060] In some implementations, heat is generated during the syngas conversion process in the plasma reactor 310. The heat (e.g., thermal energy) generated in the plasma reactor 310 increases the temperature of the first effluent stream and the temperature of the first syngas contained in the first effluent stream. For example, the temperature of the first syngas may be 1500°C to 2500°C. In some implementations, as discussed above, an integrated reformer 320 in fluid communication with the plasma reactor 310 is configured to receive the first effluent stream comprising the first syngas from the plasma reactor 310. As a result, at least a portion of the thermal energy generated in the plasma reactor 310 is transferred to the integrated reformer 320 via the first effluent stream comprising the first syngas (e.g., a syngas having a temperature greater than 1500°C).

[0061] In some implementations, the integrated reformer 320 comprises a separate reactor connected to the plasma reactor 310. Additionally or alternatively, the plasma reactor 310 and the integrated reformer 320 may be a single device, whereby the formation of syngas (e.g., second syngas) by the integrated reformer 320 occurs at a plasma reactor / integrated reformer combined unit.

[0062] In some implementations, the integrated reformer 320 includes a steam methane reforming reactor or any other reactor configured to convert a first syngas (H2 and CO), CO2, CH4, and HO from the first discharge stream of the plasma reactor, the purified biogas from the scrubber 336, and steam (e.g., superheated water) from the heat utilization unit 340 into a second syngas (included in the second discharge stream).

[0063] In some implementations, the separation unit 348 (as described in more detail below) provides additional CO to the integrated reformer 320. Thus, as shown, in some implementations, the integrated reformer 320 includes a steam methane reforming reactor or any other reactor configured to convert the first syngas (H2 and CO) from the first discharge stream of the plasma reactor 310, CO2, CH4, H2O, CO, purified biogas from the scrubber 336, steam (e.g., superheated water) from the heat utilization unit 340, and recycle gas from the separation unit 348 into a second syngas (included in the second discharge stream). As a result, additional reactants are provided to facilitate greater conversion of the first syngas and biogas into one or more product gases (the second syngas in this example).

[0064] In some implementations, the syngas resulting from the chemical reactions occurring in the PCCU 302 (the second syngas in this example) may be generated more efficiently than syngas resulting from other existing chemical processes. Additionally or alternatively, additional heat may not be required to facilitate the syngas reaction occurring in the integrated reformer 320 because the heat generated by the reactions occurring in the plasma reactor 310 may be input into the integrated reformer 320.

[0065] In some implementations, steam to the integrated reformer 320 is provided by a cooling unit 514 / 614 as described in more detail below. In some implementations, the cooling unit 514 / 614 is configured to cool the first outlet stream (including the first syngas) from the plasma reactor 310. In some implementations, the cooling unit 514 / 614 is configured to cool the first syngas to a temperature range (e.g., 700°C to 1000°C) for the steam reforming process. In some implementations, the cooling unit 514 / 614 uses water as a coolant to cool the first outlet stream (including the first syngas) from the plasma reactor 310. In some implementations, the cooling unit 514 / 614 is configured to provide steam, which is water that is heated in the process of cooling the first outlet stream (including the first syngas) from the plasma reactor 310 to the integrated reformer 320.

[0066] As shown, the integrated reformer 320 is in fluid communication with a heat utilization unit 340 (e.g., a heat exchanger). In some implementations, the fluid communication routes the second effluent stream (including the second syngas) generated by the integrated reformer 320 to the heat utilization unit 340. In some implementations, the heat utilization unit 340 is configured to cool the second effluent stream including the second syngas from the integrated reformer 320 so that the second effluent stream including the second syngas is more suitable for further processing (e.g., a CO2 removal process in an amine unit 344). In some implementations, the heat utilization unit 340 is configured to cool the second effluent stream including the second syngas to a predetermined temperature or a predetermined temperature range (e.g., 40°C to 50°C). As shown, in some implementations, water is provided to the heat utilization unit 340 as a coolant, process water, or make-up water. When the water cools the second effluent stream containing the second syngas in the heat utilization unit 340, the water absorbs heat energy from the second effluent stream containing the second syngas and therefore changes state of the water to a gas (e.g., superheated water), which can be provided to the integrated reformer 320.

[0067] As shown, in some implementations, the heat utilization unit 340 includes a power generation unit (e.g., a steam turbine). In some implementations, the power generation unit uses the steam generated in the heat utilization unit 340 to generate power (e.g., generate electricity).

[0068] As discussed above, the heat utilization unit 340 may include a steam generation unit configured to receive an input stream of water (as a coolant, process water, or make-up water) and a second output stream including the second syngas generated by the integrated reformer 320. The heat utilization unit 340 may use residual heat generated by the plasma reactor 310, which is input to the heat utilization unit 340 by the incoming second output stream (including the second syngas) from the integrated reformer 320, to vaporize or heat the input water, and the generated steam may be sent to the integrated reformer 320 to facilitate the formation of the second syngas in the integrated reformer 340.

[0069] In some implementations, the second syngas included in the second effluent stream includes hydrogen gas and carbon monoxide in a ratio ranging from 0.5:1 to 2.9:1 (e.g., a ratio of 2:1 as shown in FIG. 3). The ratio of the second syngas formed may depend on the biogas volume input into the precompressor 332, the air volume input into the air separator 338, the amount of energy provided to the plasma reactor 310 or the integrated reformer 320 of the PCCU 302, the amount of steam sent from the heat utilization unit 340 to the integrated reformer 320, or some combination thereof. For example, the ratio of hydrogen gas to carbon monoxide may range from approximately 0.5:1 to approximately 1.5:1 in the absence of a recycle stream of steam from the heat utilization unit 340 to the integrated reformer 320, but the ratio of hydrogen gas to carbon monoxide may increase from approximately 1.3:1 to approximately 2.9:1 depending on the amount of steam recycle (or provided) to the integrated reformer 320.

[0070] As shown, in some implementations, the heat utilization unit 340 is configured to receive a second discharge stream from the heat utilization unit 340 that is cooled by the heat utilization unit 340 (including the second syngas) and is in fluid communication with a compressor 334 that is configured to compress the second discharge stream. As shown, the compressor 334 is in fluid communication with an amine unit 344. In some implementations, the compressor 334 operates based on power (e.g., electricity) generated by the heat utilization unit 340 as discussed above. As a result, the compressor 334 receives the second discharge stream that is cooled by the heat utilization unit 340 and provides the "cooled" second discharge stream to the amine unit 344 after compression. For example, the second discharge stream may be obtained by the compressor 334 at a pressure of 0.5 atm, 1 atm, 1.5 atm, 2 atm, or other pressure, and the "cooled" second discharge stream exiting the compressor 334 may be at a pressure of 2 atm, 3 atm, 5 atm, 10 atm, 20 atm, 100 atm, or other pressure.

[0071] The amine unit 344 may contain an aqueous solution of various amines that react with the "cold" second bleed stream exiting the compressor 334 to remove any remaining impurities (e.g., hydrogen sulfide, sulfur oxides, or other harmful substances). Additionally or alternatively, the amines contained in the amine unit 344 may facilitate the removal of acid gases such as carbon dioxide.

[0072] As shown, in some implementations, the amine unit 344 is fluidly connected to a separation unit 348 configured to receive a “cooled” second effluent stream from the amine unit 344 (processed or prepared by the amine unit 344).

[0073] The result is a "cooled" second effluent stream (treated by amine unit 344). is sent to separation unit 348 to separate various components of the second bleed stream. For example, separation unit 348 may include a pressure swing adsorption device for separating components contained in the "cooled" second bleed stream (processed by amine unit 344), which includes an adsorbent that separates the gas components that entered the pressure swing adsorption device by filtering compounds that pass through the adsorbent. Gas captured by the adsorbent may be desorbed from the adsorbent by reducing the pressure in the pressure swing adsorption device, and the desorbed gas (e.g., CO) may be recycled to PCCU 302 (e.g., to integrated reformer 302) for further reaction. In some implementations, a first portion of the "cooled" second bleed stream (processed by amine unit 344) is processed by the pressure swing adsorption device, and a second portion of the "cooled" second bleed stream (processed by amine unit 344) bypasses the pressure swing adsorption device. In some implementations, by varying the amount of the first portion of the “cooled” second bleed stream processed by the pressure swing adsorption unit (processed by the amine unit 344), the separation unit 348 configured to bleed the total amount of the first and second portions can produce syngas with various H2:CO ratios. As a result, the carbon dioxide (CO2) reduction and utilization system 300 is capable of reducing CO2 and generating syngas with various H2:CO ratios.

[0074] Modifications, additions, or omissions may be made to the carbon dioxide reduction and utilization system 300 without departing from the scope of the present disclosure. For example, the names of the different elements as described are intended to aid in explaining the concepts described herein and are not limiting. For example, in some implementations, the pre-compressor 332, the scrubber 336, the air separator 338, the PCCU 302 including the plasma reactor 310 and the integrated reformer 320, the heat utilization unit 340, the compressor 334, the amine unit 344, and the separation unit 348 are depicted in the particular manner described to aid in explaining the concepts described herein, but such depictions are not intended to be limiting. Furthermore, the carbon dioxide reduction and utilization system 300 may include any number of other elements or be implemented within other systems or contexts other than those described.

[0075] 4 illustrates an example carbon dioxide (CO2) reduction and utilization system 400 according to some implementations of the present disclosure. The CO2 reduction and utilization system 400 may include a system for producing hydrogen from biogas.

[0076] As shown in FIG. 4, in some implementations, the CO2 reduction and utilization system 400 includes a PCCU 402 (including a plasma reactor 410 and an integrated reformer 420 in fluid communication with the plasma reactor 410), a precompressor 432, a compressor 434, a scrubber 436, an air separator 438, a heat utilization unit 440, a water gas shift reactor 442, an amine unit 444, and a pressure swing adsorption unit 446.

[0077] As shown, in some implementations, the inlet of the precompressor 432 is in fluid communication with a biogas input source. As a result, the precompressor 432 can control the pressure of the biogas steam into the system 400 (e.g., into the scrubber 436 as shown in FIG. 4). In some implementations, the precompressor 432 increases the pressure of the biogas steam into the system 400. For example, the input biogas can be obtained by the precompressor 432 at a pressure of 0.5 atm, 1 atm, 1.5 atm, 2 atm, or other pressure, and the biogas exiting the precompressor 432 (e.g., the biogas stream into the scrubber 436) can be at a pressure of 2 atm, 3 atm, 5 atm, 10 atm, 20 atm, 100 atm, or other pressure.

[0078] As shown, in some implementations, the outlet of the precompressor 432 is in fluid communication with the inlet of the scrubber 436. As a result, the scrubber 436 receives the biogas (e.g., pressurized biogas) from the precompressor 432. In some implementations, the scrubber 436 removes impurities, contaminants, or harmful components of the biogas received from the precompressor 432. For example, the scrubber 436 may include a dry purification process in which harmful substances (e.g., sulfur oxides, particulate matter, acid gases, etc.) are adsorbed onto a dry reagent contained in the scrubber 436. As another example, the scrubber 436 may include a wet purification process in which a wet material (e.g., water) is sprayed onto the biogas (from the precompressor 432) to separate one or more components from the biogas. As shown, the outlet of the scrubber 436 is in fluid communication with the plasma reactor 410 and the integrated reformer 420. As a result, a purified biogas (eg, gas containing CH4 and CO2) stream is provided to the plasma reactor 410 and the integrated reformer 420.

[0079] As shown, in some implementations, the air separator 438 takes the input air stream and separates it into its constituent components, which may primarily include nitrogen gas (N2) and oxygen gas (O2). The air separator 438 may facilitate separation of the components contained in the input air stream by fractionation, pressure swing adsorption, vacuum pressure swing adsorption, membrane separation, or by any other separation method. As shown, in some implementations, the air separator 438 is in fluid communication with the PCCU 402 (e.g., in fluid communication with the plasma reactor 410 of the PCCU 402). As shown, the fluid communication may send the separated air components to the plasma reactor 410 of the PCCU 402.

[0080] In some implementations, the plasma reactor 410 includes a plasma chamber made from quartz or ceramic materials, with one or more waveguides in the plasma chamber configured to facilitate chemical reactions occurring in the plasma chamber. As shown, in some implementations, the plasma reactor 410 is configured to obtain a biogas (e.g., purified biogas) stream from a scrubber 436, a separated air component from an air separator 438, and to affect a chemical reaction between the inlet gas stream.

[0081] In some implementations, in the plasma reactor 410, the CO2 and CH4 in the cleaned biogas stream from the scrubber 436 are converted to H2 and CO (first syngas) using a microwave plasma (e.g., by exposing the CO2 and CH4 to a microwave plasma). In some implementations, the plasma reactor 410 converts the CO2 and CH4 instantly to H2 and CO without combustion. As a result, the plasma reactor 410 continues to receive CO2 and CH4 from the scrubber 436, so that it can convert the CO2 and CH4 to the first syngas (contained in the first effluent stream).

[0082] In some implementations, in the plasma reactor 410, the mixture of gases including CO2, CH4, and O2 from the scrubber 436 and the air separator 438 is used to generate H2 and CO using microwave plasma (e.g., by exposing the mixture of CO2, CH4, and O2 to microwave plasma). In some implementations, the plasma reactor 410 instantly generates H2 and CO (first synthesis gas) using the mixture of gases including CO2, CH4, and O2 without combustion. As a result, the plasma reactor 410 continuously receives CO2, CH4, and O2, so that the mixture of gases including CO2, CH4, and O2 can be used to generate the first synthesis gas (included in the first discharge stream).

[0083] In some implementations, heat is generated during the syngas conversion process in the plasma reactor 410. The heat (e.g., thermal energy) generated in the plasma reactor 410 increases the temperature of the first effluent stream and the temperature of the first syngas contained in the first effluent stream. For example, the temperature of the first syngas may be 1500°C to 2500°C. In some implementations, as discussed above, an integrated reformer 420 in fluid communication with the plasma reactor 410 is configured to receive the first effluent stream comprising the first syngas from the plasma reactor 410. As a result, at least a portion of the thermal energy generated in the plasma reactor 410 is transferred to the integrated reformer 420 via the first effluent stream comprising the first syngas (e.g., a syngas having a temperature greater than 1500°C).

[0084] In some implementations, the integrated reformer 420 comprises a separate reactor connected to the plasma reactor 410. Additionally or alternatively, the plasma reactor 410 and the integrated reformer 420 may be a single device, whereby the formation of syngas (e.g., second syngas) by the integrated reformer 420 occurs at a plasma reactor / integrated reformer combined unit.

[0085] In some implementations, pressure swing adsorption device 448 (as described in more detail below) provides additional CO to integrated reformer 420. Thus, as shown, in some implementations, integrated reformer 420 includes a steam methane reforming reactor or any other reactor configured to convert a first syngas (H2 and CO), CO2, CH4, CO, and HO from the first outlet stream of plasma reactor 410, cleaned biogas from scrubber 436, recycle gas from pressure swing adsorption device 448, and steam (e.g., superheated water) from heat utilization unit 440 into a second syngas (included in the second outlet stream).

[0086] In some implementations, steam to the integrated reformer 420 is provided by a cooling unit 514 / 614 as described in more detail below. In some implementations, the cooling unit 514 / 614 is configured to cool the first outlet stream (including the first syngas) from the plasma reactor 410. In some implementations, the cooling unit 514 / 614 is configured to cool the first syngas to a temperature range (e.g., 700°C to 1000°C) for the steam reforming process. In some implementations, the cooling unit 514 / 614 uses water as a coolant to cool the first outlet stream (including the first syngas) from the plasma reactor 410. In some implementations, the cooling unit 514 / 614 is configured to provide steam, which is water that is heated in the process of cooling the first outlet stream (including the first syngas) from the plasma reactor 410 to the integrated reformer 420.

[0087] In some implementations, the integrated reformer 420 is configured to obtain steam from the heat utilization unit 440 and steam from the cooling unit 514 / 614, thereby providing additional reactants to facilitate greater conversion of the first syngas and biogas to one or more product gases (in this example, the second syngas).

[0088] As shown, the integrated reformer 420 is in fluid communication with a heat utilization unit 440 (e.g., a heat exchanger). In some implementations, the fluid communication routes the second effluent stream (including the second syngas) generated by the integrated reformer 420 to the heat utilization unit 440. In some implementations, the heat utilization unit 440 is configured to cool the second effluent stream including the second syngas from the integrated reformer 420 so that the second effluent stream including the second syngas is more suitable for further processing (e.g., a water-gas shift process). In some implementations, the heat utilization unit 440 is configured to cool the second effluent stream including the second syngas to a predetermined temperature or a predetermined temperature range (e.g., 300°C to 350°C). As shown, in some implementations, water is provided to the heat utilization unit 440 as a coolant, process water, or make-up water. When the water cools the second effluent stream comprising the second syngas in the heat utilization unit 440, the water absorbs heat energy from the second effluent stream comprising the second syngas. Thus, the state of the water changes to gas (e.g., superheated water), which can be provided to the integrated reformer 420 and / or the water-gas shift reactor 442.

[0089] As shown, in some implementations, the thermal utilization unit 440 includes a power generation unit (e.g., a steam turbine). In some implementations, the power generation unit uses the steam generated in the thermal utilization unit 440 to generate power (e.g., generate electricity).

[0090] As discussed above, the heat utilization unit 440 may include a steam generation unit configured to receive an input stream of water (as a coolant, process water, or make-up water) and a second output stream including the second syngas generated by the integrated reformer 420. The heat utilization unit 440 may use residual heat generated by the plasma reactor 410 to vaporize or heat the input water input to the heat utilization unit 440 by the incoming second output stream (including the second syngas) from the integrated reformer 420, and the generated steam may be sent to the water-gas shift reactor 442. In some implementations, any excess steam from the heat utilization unit 440 is sent to the integrated reformer 420 to facilitate the formation of the second syngas in the integrated reformer 440.

[0091] As shown, in some implementations, the heat utilization unit 440 is in fluid communication with the water-gas shift reactor 442. In some implementations, the fluid communication sends the second effluent stream (including the second synthesis gas) to the water-gas shift reactor 442 after the cooling step in the heat utilization unit 240. In some implementations, the water-gas shift reactor 442 facilitates the formation of H2 by the water-gas shift reactor 442, where carbon monoxide and water react reversibly to form CO2 and H2. For example, the water-gas shift reactor 442 converts CO and H2O in the second effluent stream (including the second synthesis gas) passing through the water-gas shift reactor 442 to a third effluent stream including H2 and CO2 ("product gas" in FIG. 4). As shown, in some implementations, after the water-gas shift step in the water-gas shift reactor 442, the product gas is sent back to the heat utilization unit 440 for further cooling steps. For example, the heat utilization unit 440 cools the product gas from the water gas shift reactor 442 to a predetermined temperature or to a predetermined temperature range (eg, 40° C. to 50° C.).

[0092] As shown, in some implementations, the heat utilization unit 440 is configured to receive the product gas ("cool" the product gas, including H2, CO2, and unreacted or partially reacted substances) and is in fluid communication with a compressor 434 configured to pressurize the product gas. As shown, the compressor 434 is in fluid communication with an amine unit 444. In some implementations, the compressor 434 operates based on power (e.g., electricity) generated by the heat utilization unit 440 as discussed above. As a result, the compressor 434 receives the product gas and provides the product gas to the amine unit 444 after compression. For example, the product gas may be obtained by the compressor 434 at a pressure of 0.5 atm, 1 atm, 1.5 atm, 2 atm, or other pressure, and the product gas exiting the compressor 434 may be at a pressure of 2 atm, 3 atm, 5 atm, 10 atm, 20 atm, 100 atm, or other pressure.

[0093] The amine unit 444 may contain an aqueous solution of various amines that react with the product gas exiting the compressor 434 to remove any remaining impurities (e.g., hydrogen sulfide, sulfur oxides, or other harmful substances). Additionally or alternatively, the amines contained in the amine unit 444 may facilitate the removal of acid gases such as carbon dioxide.

[0094] As shown, in some implementations, the amine unit 444 is in fluid communication with a pressure swing adsorption unit 446 configured to receive product gas from the amine unit 444. In some implementations, the product gas including hydrogen gas from the amine unit 434 and any residual gas are sent to the pressure swing adsorption unit 446 to further separate the resulting gases. In some implementations, for example, the pressure swing adsorption unit 446 includes an adsorbent that separates hydrogen gas from any other gases that entered the pressure swing adsorption unit 446 by capturing compounds that pass through the adsorbent in addition to the hydrogen gas. The gas captured by the adsorbent may be desorbed from the adsorbent by reducing the pressure in the pressure swing adsorption unit 446, and the desorbed gas (e.g., CO) may be recycled to the PCCU 402 (e.g., to the integrated reformer 420) for further reaction. In other words, the amine unit 444 and the pressure swing adsorption unit 446 remove non-hydrogen gases from the product gas including H2 and CO2 from the water-gas shift reactor 442. As a result, the carbon dioxide (CO2) reduction and utilization system 400 can remove CO2 and generate high purity H2 (eg, 99.95% H2).

[0095] Modifications, additions, or omissions may be made to the carbon dioxide reduction and utilization system 400 without departing from the scope of the present disclosure. For example, the names of the different elements as described are intended to aid in explaining the concepts described herein and are not limiting. For example, in some implementations, the precompressor 432, the scrubber 436, the air separator 438, the PCCU 402 including the plasma reactor 410 and the integrated reformer 420, the heat utilization unit 440, the water gas shift reactor 442, the compressor 434, the amine unit 444, and the pressure swing adsorption unit 446 are depicted in the particular manner described to aid in explaining the concepts described herein, but such depictions are not intended to be limiting. Furthermore, the carbon dioxide reduction and utilization system 400 may include any number of other elements or be implemented within other systems or contexts other than those described.

[0096] FIG. 5A shows a cross-sectional view of an example integrated reformer 500A according to some implementations of the present disclosure.

[0097] As shown, in some implementations, the integrated reformer 500A includes an outer chamber 502 and a reaction chamber 504.

[0098] As shown, in some implementations, the outer chamber 502 includes a first inlet 506 configured to obtain a first gas stream (e.g., a gas stream including a first syngas from a plasma reactor) and a second inlet 508 configured to obtain a second gas stream (e.g., a gas stream including a hydrocarbon fuel, such as biogas, CH4, natural gas, or any combination thereof).

[0099] As shown, in some implementations, the second gas stream is from a heat utilization section 540 (e.g., a heat utilization unit similar to heat utilization unit 240 / 340 / 440 in FIGS. 2 / 3 / 4). In some implementations, the second gas stream is heated or cooled to a predetermined temperature by the heat utilization unit 540 before being introduced into the chamber 502.

[0100] In some implementations, the integrated reformer 500A provides a mixing and cooling zone 510 in the outer chamber 502 where the first and second gas streams are mixed and cooled. As shown, in some implementations, the first end 512 of the second inlet 508 extends into the mixing and cooling zone 510 through the wall of the outer chamber 502 to mix the first and second gas streams in the mixing and cooling zone 510. As shown, in some implementations, the first end 512 of the second inlet 508 in the outer chamber 502 is bent such that the first end 512 of the second inlet 508 is directed toward the first inlet 506. Therefore, the first and second gas streams collide directly in the mixing and cooling zone 510 for better mixing.

[0101] In some implementations, the first gas stream is from a plasma reactor, such as the first discharge stream (including the first syngas) from the plasma reactor described with respect to Figures 2, 3, and 4. As discussed, the first discharge stream from the plasma reactor (the first gas stream in Figure 5) has a high temperature (e.g., a temperature range of 1500°C to 2500°C) due to operation of the plasma reactor.

[0102] By mixing the (hot) first gas stream with a second gas stream (biogas in this example) that is at a relatively lower temperature than the first gas stream, the temperature of the mixture of the first and second gas streams is lower than the temperature of the first gas stream. In some implementations, the cooling unit 514 is coupled to the outer chamber 502 to efficiently cool the mixture of the first and second gas streams to a predetermined temperature or range of temperatures such that the temperature of the mixture of the first and second gas streams (in the reaction chamber 504 with steam) is within a suitable range for steam reforming (e.g., 700° C.-1000° C.).

[0103] As shown, in some implementations, the integrated reformer 500A includes a cooling unit 514 disposed adjacent to the mixing and cooling zone 510. As shown, in some implementations, the cooling unit 514 surrounds the mixing and cooling zone 510. As shown, in some implementations, the cooling unit 514 includes a tube 516 (or pipe) disposed or wrapped around the outer chamber 502 adjacent to the mixing and cooling zone 510. As shown, in some implementations, the mixing and cooling zone 510 is provided between the first inlet 506 and the reaction chamber 504.

[0104] In some implementations, the cooling unit 514 uses water as a coolant to cool the mixture of the first and / or second gas streams. For example, water is provided to a first end 518 of a tube 516 disposed around the outer chamber 502. As the water flows into the tube 516, the water absorbs thermal energy (heat) from the mixture of the first and / or second gas streams and becomes steam (e.g., water in a gaseous state).

[0105] As shown, in some implementations, the cooling unit 514 is configured to provide steam to the reaction chamber 504. As shown, the second end 520 of the tube 516 is disposed in the reaction chamber 504 adjacent to a mixed gas inlet 522 of the reaction chamber 504. As shown, in some implementations, the second end 520 of the tube 516 is connected to (or in fluid communication with) the reaction chamber 504 via the mixed gas inlet 522 of the reaction chamber 504.

[0106] As shown, in some implementations, the second end 520 of the tube 516 is directed to the opposite side of the mixed gas inlet 522. As shown, the mixture of the first gas stream and the second gas stream is provided to the reaction chamber 504 via the mixed gas inlet 522. As a result, the mixture of the first gas stream and the second gas stream is mixed with steam in the reaction chamber 504. As a result, in the reaction chamber 504, a third gas stream (including the second syngas) is generated based on the first gas stream, the second gas stream, and the steam using steam reforming. As shown, the reaction chamber 504 includes an outlet 524 for discharging the third gas stream (including the second syngas) generated by the integrated reformer 500A. As shown, in some implementations, the reaction chamber 504 includes a catalyst 526 for promoting more reactions for syngas production (e.g., catalytic process). In some implementations, the catalyst comprises a porous material or structure (e.g., a mesh, multiple tubes or pipes, a membrane). As shown, the catalyst 526 is disposed between the outlet 524 and the mixed gas inlet 522 so that the mixture of the first gas stream, the second gas stream, and the steam from the cooling unit 514 can efficiently pass through the catalyst 526 for the catalytic process.

[0107] Modifications, additions, or omissions may be made to the integrated reformer 500A without departing from the scope of the present disclosure. For example, the coolant in the cooling unit 514 may be used only to cool the mixture of the first gas stream and / or the second gas stream, and steam from the heat utilization unit (as discussed above) may be used for the steam reforming process. In this case, the coolant may be reused after condensation by the cooling unit 514 after cooling the mixture of the first gas stream and / or the second stream.

[0108] FIG. 5B illustrates a cross-sectional view of an example integrated reformer 500B according to some implementations of the present disclosure.

[0109] As shown, the integrated reformer 500B is substantially similar to the integrated reformer 500A in Figure 5A, and therefore, overlapping details will not be repeated here.

[0110] As shown, in some implementations, the steam inlet 520B of the reaction chamber 504 is in fluid communication with the heat utilization unit 540. In some implementations, steam from the heat utilization unit is provided to the reaction chamber 504 in addition to the coolant from the cooling device 514 to generate a third gas flow. In some implementations, steam from the heat utilization unit is provided to the reaction chamber 504 instead of the coolant from the cooling device 514 to generate a third gas flow.

[0111] In some implementations, the coolant in the cooling unit 514 is used only to cool the mixture of the first gas stream and / or the second gas stream, and the steam from the heat utilization unit 540 is used for the steam reforming process. In this case, the coolant may be reused after condensation / cooling by the cooling unit 514 after cooling the mixture of the first gas stream and / or the second stream.

[0112] In some implementations, the coolant includes water. In some implementations, the coolant includes CO2. In some implementations, the coolant includes CH4. In some implementations, the coolant includes oil. In some implementations, the coolant includes a substance suitable for cooling the first gas stream (e.g., to a temperature of 1500° C. or greater).

[0113] FIG. 6A shows a cross-section of an example integrated reformer 600A according to some implementations of the present disclosure.

[0114] As shown, in some implementations, the integrated reformer 600A includes a chamber 602 (referred to as the outer chamber).

[0115] As shown, in some implementations, the chamber 602 includes a first inlet 606 configured to obtain a first gas stream (e.g., a gas stream comprising a first syngas), a second inlet 608 configured to obtain a second gas stream (e.g., a gas stream comprising a hydrocarbon fuel, such as biogas, CH4, natural gas, or any combination thereof), and a third inlet 609 for obtaining steam.

[0116] As shown, in some implementations, the second gas stream is from a heat utilization section 640 (e.g., a heat utilization unit similar to heat utilization unit 240 / 340 / 440 in FIGS. 2 / 3 / 4). In some implementations, the second gas stream is heated or cooled to a predetermined temperature by the heat utilization unit 640 before being introduced into the chamber 602.

[0117] In some implementations, the chamber 602 includes a mixing and cooling zone 610 in the chamber 602 where the first gas stream, the second gas stream, and the steam are mixed and cooled.

[0118] In some implementations, the first gas stream is from a plasma reactor, such as the first discharge stream (including the first syngas) from the plasma reactor described with respect to Figures 2, 3, and 4. As discussed, the first discharge stream from the plasma reactor (the first gas stream in Figure 6) has a high temperature (e.g., a temperature range of 1500°C to 2500°C) due to operation of the plasma reactor.

[0119] By mixing the (hot) first gas stream with a second gas stream (biogas in this example) at a relatively lower temperature than the first gas stream and steam at a relatively lower temperature than the first gas stream, the temperature of the mixture of the first gas stream, the second gas stream, and steam is lower than the temperature of the first gas stream. In some implementations, a cooling unit 614 is coupled to the chamber 602 to efficiently cool the mixture of the first gas stream, the second gas stream, and steam to a predetermined temperature or range of temperatures suitable for steam reforming (e.g., 700° C.-1000° C.).

[0120] As shown, in some implementations, the integrated reformer 600A includes a cooling unit 614 disposed adjacent to the mixing and cooling zone 610. As shown, in some implementations, the cooling unit 614 includes a tube 616 (or pipe) disposed around the outer chamber 602 adjacent to the mixing and cooling zone 610. As shown, in some implementations, the mixing and cooling zone 610 is between the first inlet 606 and the reaction zone 604. As shown, in some implementations, when a catalyst 626 is included in the integrated reformer 600A, the mixing and cooling zone 610 is between the first inlet 606 and the catalyst 626 disposed in the chamber 602. As shown, in some implementations, the mixing and cooling zone 610 is between the second inlet 608 and the third inlet 609.

[0121] In some implementations, the cooling unit 614 uses water as a coolant to cool the first gas stream mixture. For example, water is provided to a first end 618 of a tube 616 disposed about the chamber 602. As the water flows within the tube 616, the water absorbs thermal energy (heat) from the first gas stream and turns into steam.

[0122] As shown, in some implementations, the cooling unit 614 is configured to provide steam to the chamber 602. As shown, a second end 620 of the tube 616 is coupled to a third inlet 609 to provide steam to the mixing and cooling zone 610.

[0123] As a result, a third gas stream (including a second syngas) is generated in the chamber 602 based on the first gas stream, the second gas stream, and the steam using steam reforming. As shown, the chamber 602 includes an outlet 624 for releasing the third gas stream (including the second syngas) generated by the integrated reformers 500A,B.

[0124] As shown, in some implementations, a reaction zone 604, which may include a catalyst 626, is disposed between the outlet 624 and the first inlet 606 so that a mixture of the first gas stream, the second gas stream, and steam from the cooling unit 514 can efficiently pass through the reaction zone 604 to promote more reactions for syngas production. For similar reasons, when the reaction zone 604 includes a catalyst 626, a mixture of the first gas stream, the second gas stream, and steam can efficiently pass through the catalyst 626 to promote more reactions for syngas production (e.g., catalytic process).

[0125] As shown, in some implementations, the catalyst 626 comprises a porous material or structure (eg, a mesh, multiple tubes or pipes, a membrane).

[0126] Modifications, additions, or omissions may be made to the integrated reformer 600A without departing from the scope of the present disclosure. For example, the coolant in the cooling unit 614 may be used only to cool the first gas stream, and steam from the heat utilization unit (as discussed above) may be used for the steam reforming process. In this case, the coolant may be reused after condensation by the cooling unit 614 after cooling the first gas stream mixture.

[0127] FIG. 6B illustrates a cross-sectional view of an example integrated reformer 600B according to some implementations of the present disclosure.

[0128] As shown, the integrated reformer 600B is substantially similar to the integrated reformer 600A in Figure 6A, and therefore, overlapping details will not be repeated here.

[0129] As shown, in some implementations, the third inlet 609 is in fluid communication with the heat utilization unit 640. In some implementations, steam from the heat utilization unit 640 is provided to the chamber 602 in addition to the coolant (e.g., steam) from the cooling device 614 to generate a third gas flow. In some implementations, steam from the heat utilization unit 640 is provided to the chamber 602 instead of the coolant from the cooling device 614 to generate a third gas flow.

[0130] In some implementations, the coolant in the cooling unit 614 is used only to cool the first gas stream, and the steam from the heat utilization unit 640 is used for the steam reforming process. In this case, the coolant can be reused after condensation by the cooling unit 614 after cooling the mixture of the first gas stream.

[0131] In some implementations, the coolant includes water. In some implementations, the coolant includes CO2. In some implementations, the coolant includes CH4. In some implementations, the coolant includes oil.

[0132] FIG. 7 illustrates a flow chart of an example method 700 for a plasma carbon converter according to certain implementations of the present disclosure. The method 700 may be performed by any component, including the plasma carbon converter 102, the integrated reformer 120, or any other component or subcomponent. For ease of explanation, the methods described herein are illustrated and described as a series of acts. However, acts according to the present disclosure may occur in various orders and / or simultaneously, and other acts are not shown or described herein. Furthermore, not all acts shown may be used to implement a method in accordance with the disclosed subject matter. Furthermore, one skilled in the art will understand and appreciate that a method may alternatively be represented as a series of interrelated states by a state diagram or events. Although various blocks are illustrated as separate blocks, they may be divided into additional blocks, combined into fewer blocks, or eliminated, depending on the desired implementation.

[0133] The method 700 includes, at operation 702, receiving a first gas flow from a plasma reactor into the outer chamber. At operation 704, the method includes receiving a second gas flow into the outer chamber, where the second gas flow may include a coolant such as water / steam. At operation 706, the method includes absorbing thermal energy from the first gas flow by a cooling unit. At operation 708, the method includes releasing a third gas flow based on a reaction caused by the first gas flow and the second gas flow.

[0134] Terms used in this disclosure, and particularly in the appended claims (e.g., the body of the appended claims), are generally intended to be "open language" (e.g., the term "including" should be interpreted as "including, but not limited to").

[0135] Furthermore, if a specific number of claim recitations to be introduced is intended, such intent will be expressly recited in the claims, and in the absence of such recitation, such intent does not exist. For example, as an aid to understanding, the following appended claims may contain the use of the preambles "at least one" and "one or more" to introduce claim recitations. However, the use of such phrases should not be interpreted as implying that the introduction of a claim recitation with the indefinite article "a" or "an" limits any particular claim that includes a claim recitation so introduced to an implementation that includes only one such recitation, even when the same claim includes the preamble "one or more" or "at least one" and an indefinite article such as "a" or "an" (e.g., "a" and / or "an" should be interpreted to mean "at least one" or "one or more"). The same applies to the use of definite articles used to introduce claim recitations.

[0136] Moreover, even if a particular number of claim recitations introduced is explicitly recited, as one of ordinary skill in the art will recognize, such recitation should be interpreted to mean at least the number of recitations (e.g., the bare recitation of "two recitations" without other modifiers means at least two recitations, or more than two recitations). Also, in instances where idiomatic language similar to "at least one of A, B, and C, etc." or "one or more of A, B, and C, etc." is used, such construction is generally intended to include A only, B only, C only, A and B together, A and C together, B and C together, or A, B, and C together, etc.

[0137] Furthermore, a disjunction or phrase preceding two or more alternative terms, whether in the specification, claims, or drawings, should be understood to contemplate the possibility of including one of those terms, either of those terms, or both of those terms. For example, the phrase "A or B" should be understood to include the possibilities of "A" or "B" or "A and B."

[0138] All examples and conditional language described in this disclosure are intended for educational purposes to help the reader understand the disclosure and the concepts provided by the inventor to advance the art, and should not be construed as limitations to the examples and conditions specifically described as such. Although implementations of the present disclosure have been described in detail, various changes, substitutions, and alterations may be made to these implementations without departing from the spirit and scope of the present disclosure.

Claims

1. An outer chamber; and a first inlet configured to obtain a first gas flow into a first space in the outer chamber; a second inlet configured to obtain a second gas flow into the first space in the outer chamber; a cooling unit associated with the outer chamber; The cooling unit is configured to absorb thermal energy from the first gas flow.

2. The apparatus of claim 1 , wherein the cooling unit is disposed adjacent to the first inlet.

3. The cooling unit is configured to receive a coolant, the coolant being H ２ O, oil, CO ２ , or C.H. ４ The apparatus of claim 1 , comprising at least one of:

4. The apparatus of claim 1 , wherein the cooling unit includes a tube disposed about the outer chamber.

5. the tube includes a coolant inlet configured to receive a coolant; The apparatus of claim 4 , wherein the tube includes a coolant outlet configured to discharge the coolant that has absorbed the thermal energy from the first gas flow.

6. The coolant received by the coolant inlet is in a liquid state. ２ Contains O, The coolant from the coolant outlet is in a gaseous state. ２ The apparatus of claim 5 , further comprising:

7. The apparatus of claim 5 , wherein the coolant from the coolant outlet is provided to the first space in the outer chamber.

8. a reaction chamber in the outer chamber, The apparatus of claim 5 , wherein the coolant from the coolant outlet, the first gas flow, and the second gas flow are provided to a second space in the reaction chamber.

9. further comprising a catalyst in the reaction chamber; The apparatus of claim 8 , wherein the coolant from the coolant outlet, the first gas flow, and the second gas flow pass through the catalyst.

10. The apparatus of claim 9 , wherein the catalyst comprises a porous material.

11. an outlet configured to release a third gas flow from the reaction chamber; The apparatus of claim 8 , wherein the third gas flow is based on a reaction caused by the first gas flow, the second gas flow, and the coolant from the coolant outlet.

12. the first gas stream comprises a first synthesis gas; the second gas stream comprises a hydrocarbon fuel; The apparatus of claim 11 , wherein the third gas stream comprises a third syngas.

13. The hydrocarbon fuel may be biogas, natural gas, or CH ４ The apparatus of claim 12 , comprising at least one of:

14. The apparatus of claim 12 , wherein the hydrocarbon fuel is preheated prior to the outer chamber.

15. Further comprising an outlet; The apparatus of claim 7 , wherein the outlet emits a third gas stream based on a reaction caused by the first gas stream, the second gas stream, and the coolant from the coolant outlet.

16. 16. The apparatus of claim 15, further comprising a catalyst between the first inlet and the outlet.

17. the first gas stream comprises a first synthesis gas; the second gas stream comprises a hydrocarbon fuel; The apparatus of claim 15 , wherein the third gas stream comprises a second syngas.

18. The hydrocarbon fuel may be biogas, natural gas, or CH ４ 20. The apparatus of claim 17, comprising at least one of:

19. The apparatus of claim 17 , wherein the hydrocarbon fuel is preheated prior to the outer chamber.

20. The apparatus of claim 5 , wherein steam from a steam generating unit is provided to the first space in the outer chamber.

21. Further comprising an outlet; 21. The apparatus of claim 20, wherein the outlet emits a third gas stream based on a reaction caused by the first gas stream, the second gas stream, and the steam from the steam generating unit.

22. a reaction chamber in the outer chamber, The apparatus of claim 5 , wherein steam from a steam generating unit, the first gas flow, and the second gas flow are provided to a second space in the reaction chamber.

23. Further comprising an outlet; 22. The apparatus of claim 21, wherein the outlet emits a third gas stream based on a reaction caused by the first gas stream, the second gas stream, and the vapor.

24. 10. The apparatus of claim 1, wherein the apparatus includes an integrated reformer contained in a plasma carbon converter unit (PCCU), the PCCU including a plasma reactor in fluid communication with the integrated reformer.

25. 1. A method for plasma carbon conversion comprising: receiving a first gas flow into an outer chamber from a plasma reactor; receiving a second gas flow into the outer chamber; and absorbing thermal energy from the first gas stream with a cooling unit.

26. 26. The method of claim 25, wherein the first gas flow is received at a first inlet and the second gas flow is received at a second inlet.

27. 26. The method of claim 25, further comprising providing the first gas flow, the second gas flow, and a coolant to a reaction chamber in the outer chamber.

28. the first gas stream comprises a first synthesis gas; The method of claim 25 , wherein the second gas stream comprises a hydrocarbon fuel.

29. 26. The method of claim 25, wherein the second gas stream is preheated prior to the outer chamber.

30. 26. The method of claim 25, wherein steam from a steam generating unit is received in the outer chamber.

31. 26. The method of claim 25, further comprising releasing a third gas stream based on a reaction caused by the first gas stream and the second gas stream.

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