Use of intermittent energy in the production of chemicals

Abstract

To provide enhanced systems and methods of chemical synthesis that reduce or eliminate the amount of fuel, particularly fossil fuel, that is burned to provide energy.SOLUTION: A chemical synthesis plant comprising a reactor configured for producing a process stream comprising a chemical product from a reactant; a feed preparation system configured to prepare a feed stream of the reactant for introduction into the reactor; and / or a product purification system configured to separate the chemical product from a reaction byproduct, unreacted reactant, or a combination thereof within the process stream, wherein the chemical synthesis plant is configured such that a majority of the net energy required for heating, cooling, compression, or a combination thereof utilized via the reactor, the feed preparation system, the product refining system, or a combination thereof is supplied from the intermittent energy source (IES).SELECTED DRAWING: Figure 3

Description

[Technical Field]

[0001] Technical Field The present disclosure relates to the use of intermittent energy sources (IES), which may be non-carbon-based and / or renewable energy sources, in the production of chemicals. More particularly, the present disclosure relates to the electrification of chemical synthesis plants utilizing electricity from IES. Even more particularly, the present disclosure relates to systems and methods for operating chemical synthesis plants having IES. [Background technology]

[0002] background Chemical synthesis plants are utilized to provide a variety of chemicals. Often, dedicated fuels are burned or "combusted" to provide heat of reaction for chemical synthesis, energy to heat one or more process streams, energy to vaporize liquids (e.g., boil water used as a diluent), energy to do work (e.g., drive compressors or pumps), or energy for other process operations throughout the chemical synthesis plant. Burning or combusting fuels in this manner produces flue gases that can be harmful to the environment and also reduces the energy efficiency of the process. Similarly, water vapor is often traditionally utilized as a plant-wide heat and / or energy transfer fluid within chemical synthesis plants. The water vapor utilized for heat and / or energy transfer is often generated by the combustion of fuel, resulting in the generation of additional flue gases and further reducing energy efficiency during chemical synthesis. Furthermore, the use of materials that could otherwise be utilized as reactants for combustion as fuel also reduces the amount of desired chemical product produced in a chemical synthesis plant from a given amount of material. Therefore, there is a need for enhanced systems and methods of chemical synthesis that reduce or eliminate the amount of fuel, particularly fossil fuels, burned to provide energy. Desirably, such systems and methods would also result in increased energy efficiency and / or reduced emissions, such as greenhouse gas (GHG) emissions, by chemical synthesis plants. Summary of the Invention

[0003] overview Disclosed herein is a chemical synthesis plant comprising: one or more reactors configured to produce a process stream comprising at least one chemical product from one or more reactants; a feed preparation system configured to prepare one or more feed streams comprising one or more of the one or more reactants for introduction into the reactor(s); and / or a product purification system configured to separate the at least one chemical product from reaction by-products, unreacted reactants, or combinations thereof in the process stream, wherein the chemical synthesis plant is configured such that a majority (e.g., greater than 50%, greater than 60%, greater than 70%, greater than 80%, greater than 90%, or greater than 100%) of the net energy required for heating, cooling, compression, or combinations thereof utilized via the one or more reactors, feed preparation system, product purification system, or combinations thereof is supplied from an intermittent energy source (IES).

[0004] Also disclosed herein are chemical synthesis plants configured for operation that utilize electricity from renewable intermittent energy sources (IES) to provide a majority (e.g., greater than 50%, greater than 60%, greater than 70%, greater than 80%, greater than 90%, or greater than 100%) of the net energy required for heating, cooling, compression, or a combination thereof. [The present invention 1001] one or more reactors configured to produce a process stream comprising at least one chemical product from one or more reactants; a feed preparation system configured to prepare one or more feedstreams containing one or more of the one or more reactants for introduction into the reactor; and a product purification system configured to separate the at least one chemical product from reaction by-products, unreacted reactants, or combinations thereof in the process stream. A chemical synthesis plant comprising: the chemical synthesis plant is configured such that at least 50% of the net energy required for heating, cooling, compression, or a combination thereof utilized via one or more of the reactors, the feed preparation system, the product purification system, or a combination thereof, is supplied from an intermittent energy source (IES); the plant consumes an average daily amount of at least 25 MW of electricity for the heating, cooling, compression, or combination thereof; The chemical synthesis plant. [The present invention 1002] 1001. A chemical synthesis plant according to claim 1001, which does not include a flue gas heat recovery section. [The present invention 1003] one or more compressors configured to compress at least one stream comprising one or more of said reactants, at least one of said chemical products, or at least one intermediate produced by said process; a storage device configured to store the at least one compressed stream for later use. Furthermore, Apparatus for expanding said at least one stored compressed stream to generate electricity or to perform mechanical work. The chemical synthesis plant of the present invention 1001 further comprises: [The present invention 1004] a cooling device configured to cool at least one stream selected from one or more of said reactants, at least one of said chemical products, or at least one intermediate produced by said process; and a storage device configured to store the at least one cooled stream for later use. Furthermore, the at least one cooled stream comprises a cryogenic liquid; The chemical synthesis plant of the present invention 1001. [The present invention 1005] one or more reactors, feed preparation systems, product purification systems, or combinations thereof, are configured for the production of hydrogen; the chemical synthesis plant further comprising a fuel cell for converting at least a portion of the produced hydrogen into electricity; The chemical synthesis plant a hydrogen storage device for storing at least a portion of the produced hydrogen prior to converting at least a portion of the produced hydrogen into electricity using the fuel cell when an intermittent power source is not available. Furthermore, a compressor upstream of the hydrogen storage device configured to compress the hydrogen before storing the hydrogen; Further provided with The chemical synthesis plant of the present invention 1001. [The present invention 1006] The chemical synthesis plant of the present invention 1001, wherein one or more reactors, feed preparation systems, product purification systems, or combinations thereof are configured for the production of hydrogen, the chemical synthesis plant further comprising a hydrogen storage device and a compressor upstream of the hydrogen storage device, the compressor configured to compress at least a portion of the produced hydrogen before storage, and the chemical synthesis plant further comprising a combustion device for combusting a portion of the stored hydrogen to produce steam or heat when intermittent power is not available, the steam being used as a reactant or diluent. [The present invention 1007] The chemical synthesis plant of the present invention 1001 further comprising an apparatus for storing energy by increasing mass when an intermittent power source is available, the mass comprising one or more feeds, one or more products, or water. [The present invention 1008] 1001. A chemical synthesis plant according to claim 10, wherein one or more reactors are lined with a refractory material such that a brief loss of power does not cause a temperature drop of more than about 10°C in two minutes in the one or more refractory-lined reactors. [The present invention 1009] 1001. A chemical synthesis plant according to claim 1001, wherein one or more reactors are thermally connected to a thermal mass such that a brief loss of power does not cause a significant temperature drop of more than about 5°C in two minutes in the one or more refractory-lined reactors. [The present invention 1010] 1001. A chemical synthesis plant according to claim 1001, wherein one or more reactors are thermally connected to a phase change material such that a brief loss of power does not cause a temperature drop of more than about 4°C in two minutes in the one or more refractory-lined reactors. [The present invention 1011] The chemical synthesis plant of the present invention 1001 further comprising a device operable to store heat as a heated or superheated fluid for heating one or more process streams when an IES is not available. [The present invention 1012] The chemical synthesis plant of the present invention 1001 further comprising an apparatus configured to utilize liquefaction of a phase change material to store energy. [The present invention 1013] The chemical synthesis plant of the present invention 1001 further comprises a backup power device configured to supply backup power to at least one device of the chemical synthesis plant, the backup power device being selected to provide sufficient energy to ensure safe shutdown of the plant, and the backup power device comprising a device powered by compressed gas, a capacitor, a superconductor, a thermal battery, and / or a flywheel. [The present invention 1014] The chemical synthesis plant of the present invention 1001 further comprising a system for receiving information regarding energy prices and availability, whereby this information can be utilized to optimize energy usage, energy storage, and plant operation. [The present invention 1015] When IES is not available and / or above a threshold price, pressurized stored oxygen and / or nitrogen may be utilized as reactants and / or to generate electricity by expansion in an expander; an air separation unit (ASU) configured to produce oxygen and nitrogen; a storage device configured to store under pressure at least a portion of the produced oxygen and / or nitrogen; Expander and The chemical synthesis plant of the present invention 1001 further comprises: [The present invention 1016] preparing one or more feedstreams comprising one or more reactants for introduction into the reactor; reacting the one or more reactants in the reactor to produce a product stream comprising one or more chemical products; separating the one or more chemical products from reaction by-products, unreacted reactants, or combinations thereof within the product stream; recycling one or more of the unreacted reactants and / or reaction by-products; and providing at least 50% of the net energy required for powering, pumping, heating, cooling, compressing, separating, or a combination thereof utilized for one or more of said preparing, said reacting, said separating, said recycling, or a combination thereof, with electricity generated from said renewable intermittent energy sources (IES), if such sources are available; 1. A method for producing one or more chemical products, comprising: the plant consumes an average daily amount of at least 25 MW of electricity for said heating, cooling, compression, or combination thereof; The method. [Brief explanation of the drawings]

[0005] For a more complete understanding of the present disclosure and its advantages, reference is now made to the following brief description taken in conjunction with the accompanying drawings and detailed description, wherein like reference numerals represent like parts.

[0006] [Figure 1] 1 shows a schematic diagram of a typical prior art chemical process. [Figure 2]FIG. 1 shows a conceptual diagram of a chemical process that can be powered by renewable intermittent energy, according to an embodiment of the present disclosure. [Figure 3] FIG. 1 shows a block flow diagram of a generalized chemical synthesis plant I that can be powered by a renewable intermittent energy source (IES), according to an embodiment of the present disclosure. [Figure 4] FIG. 1 shows a schematic diagram of a chemical synthesis plant II that can be powered by a renewable intermittent energy source (IES), according to an embodiment of the present disclosure. [Figure 5A] FIG. 3A is a schematic diagram of a system IIIA for storing energy by compression, according to an embodiment of the present disclosure. [Figure 5B] FIG. 3B is a schematic diagram of a system IIIB for storing energy through cooling, according to an embodiment of the present disclosure. [Figure 5C] FIG. 3C is a schematic diagram of a system IIIC for storing energy by hydrogen, according to an embodiment of the present disclosure. [Figure 5D] FIG. 3D is a schematic diagram of a system IIID for storing energy by heating, according to an embodiment of the present disclosure. [Figure 6] 1 shows the operating parameters of olefin synthesis process VII implemented according to one embodiment of the present disclosure and shown in Examples 1 and 2. [Figure 7] FIG. 1 shows the operating parameters of ammonia synthesis process XII as implemented in accordance with one embodiment of the present disclosure and as shown in Examples 3 and 4. [Figure 8] FIG. 1 shows the operating parameters of methanol synthesis process X / XI implemented according to one embodiment of the present disclosure and shown in Examples 5 and 6. DETAILED DESCRIPTION OF THE INVENTION

[0007] Detailed Description While exemplary implementations of one or more aspects are provided below at the outset, it should be understood that the disclosed compositions, methods, and / or products may be implemented using any number of technologies, whether currently known or yet to exist. The present disclosure should in no way be limited to the exemplary implementations, drawings, and technologies illustrated below, including the exemplary designs and implementations shown and described herein, but may vary within the scope of the appended claims, along with their full range of equivalents.

[0008] Although the following terms are believed to be well understood by those of ordinary skill in the art, the following definitions are provided to facilitate the description of the subject matter of this disclosure. Unless otherwise defined, all technical and scientific terms used herein have the same meaning as commonly understood by one of ordinary skill in the art to which this disclosed subject matter belongs.

[0009] As used herein, an "intermittent energy source" or "IES" is any energy source that is not continuously available for conversion to electricity and is not continuously available outside of its direct control because the energy used cannot be stored or is economically undesirable. The availability of an intermittent energy source can be predictable or unpredictable. A renewable intermittent energy source is an intermittent energy source that is also a renewable energy source, as defined below. "Intermittent electricity" refers to electricity generated from an IES.

[0010] As used herein, "renewable energy" and "non-fossil energy (E NF ) includes energy obtained from natural ongoing processes and sustainable sources that are rapidly being replaced by nuclear energy. Hence the terms "renewable energy" and "non-fossil energy (E) NF) refers to energy obtained from non-fossil fuel sources (e.g., energy not produced by burning fossil fuels such as coal or natural gas), and is often referred to as "non-renewable" or "fossil energy (E)." F ) is energy obtained from fossil fuel-based sources (e.g., energy produced by burning fossil fuels). Fossil fuels are natural fuels such as coal or gas that were formed in the geological past from the remains of living organisms. Therefore, as used herein, "renewable" and "non-fossil energy (E)" are used interchangeably. NF ) includes, without limitation, wind, solar, water / moving, or biomass, which do not become depleted when used, in contrast to "non-renewable" energy from sources such as fossil fuels, which become depleted when used. Renewable energy is therefore a type of renewable energy that is not depleted when used. F ) and includes biofuels.

[0011] As used herein, "non-carbon based energy (E NC ) is energy obtained from non-carbon-based sources (e.g., energy not produced by the combustion of carbon-based fuels such as hydrocarbons), and is not carbon-based energy (E C ) is energy obtained from carbon-based energy sources (e.g., energy produced by burning carbon-based fuels such as hydrocarbons). Nuclear energy, as used herein, is defined as renewable, non-fossil (E) energy. NF )-based energy and non-carbon-based energy (E NC ) is considered to be the carbon-based energy (E C ) can be renewable (e.g., non-fossil fuel-based) or non-renewable (e.g., fossil fuel-based). For example, various carbon-based biofuels are considered renewable carbon-based energy sources herein.

[0012] As used herein, "renewable electricity" refers to electricity generated from renewable energy sources, and "non-renewable electricity" refers to electricity generated from non-renewable energy sources. As used herein, "non-carbon-based electricity" refers to electricity generated from non-carbon-based energy sources, and "carbon-based electricity" refers to electricity generated from carbon-based energy sources.

[0013] For example, in embodiments, renewable electricity and / or heat for an entire chemical synthesis plant disclosed herein can be provided by the combustion of renewable hydrocarbons derived from renewable (e.g., biological) sources. For example, renewable electricity can be generated, in embodiments, from E2O3, including methane produced in a digester fed with agricultural waste. NF / E C It can be produced by combustion of an energy source. Similarly, in embodiments, E includes synthesis gas produced using short-cycle carbonaceous waste materials. NF / E C The energy source may be utilized as a fuel (e.g., combusted to generate renewable electricity and / or heat), and desirably, the carbon dioxide produced by such combustion is recaptured (e.g., by growing new crops).

[0014] As used herein, "external" combustion of a fuel refers to burning the fuel outside of the reactor, e.g., in a furnace. Combustion as part of a primary reaction (e.g., combustion that occurs with reforming in autothermal reforming (ATR)) is not considered "external" combustion. As used herein, a "dedicated" fuel is a fuel or portion of a feedstream that is introduced solely to provide a fuel ratio (e.g., heat of combustion) and is not converted to products.

[0015] As used herein, "heat transfer steam (S HT )" refers to water vapor that is produced solely or primarily as an energy or heat transfer medium (e.g., water vapor that is not utilized as a diluent and / or reactant).

[0016] As used herein, "net" heat input or removal refers to heat input or removal that results in primary energy consumption, e.g., heat input or removal that is not supplied from another section or stream of the plant, e.g., not supplied via heat exchange with another process stream. Similarly, "net" energy refers to energy that results in primary energy consumption, e.g., energy that is not supplied from another section or stream of the plant, e.g., thermal energy that is not supplied via heat exchange with another process stream.

[0017] As used herein, "power supply" refers to the supply of mechanical and / or electrical energy.

[0018] As used herein, "heating" refers to supplying thermal energy. As used herein, "cooling" refers to removing thermal energy therefrom. As used herein, "direct" heating or cooling refers to heating or cooling without the use of a heat transfer medium / fluid. "indirect" heating or cooling refers to heating or cooling via a heat transfer medium / fluid.

[0019] As used herein, "most" or "majority" refers to more than 50% or more than half.

[0020] As used herein, a "desired" parameter (e.g., a desired temperature) may refer to the intended or target value of the parameter, e.g., a predetermined value such as a set point used in process control.

[0021] Amount of electricity consumed: References to the consumption of electricity may refer to the rate at which electricity is used (e.g., in MW), measured at a particular location. For example, the rate may be calculated at the boundary of each electrified furnace or at the boundary of the overall olefin synthesis plant. This calculation may take into account all electricity used within the location.

[0022] Flue Gas: A mixture of gases that may be produced by burning fuel or other materials in power and / or industrial plants and that may be extracted through a duct.

[0023] Flue gas heat recovery: Flue gas heat recovery may refer to the extraction of useful thermal energy from hot flue gas, for example, by passing the hot flue gas through one or more heat exchangers to raise the temperature of a relatively low-temperature process fluid and / or change the phase of the fluid (e.g., boiling water to produce steam). Any energy remaining in the flue gas after any flue gas heat recovery may be referred to as flue gas (energy) loss. A flue gas heat recovery section may be the equipment used to recover flue gas heat and the corresponding location of the equipment. The absence of a flue gas heat recovery section may mean that there is no equipment or area where heat is recovered from the hot flue gas.

[0024] Convection Section: A convection section can be a portion of a furnace (e.g., a steam cracking furnace or a reformer) where heat is recovered from hot flue gas by convection heat transfer. The absence of a convection section can mean the absence of equipment or areas where heat is recovered from hot flue gas by convection heat transfer.

[0025] "Water Vapor-Free" or "Substantially Water Vapor-Free": "Water vapor-free" can refer to a process in which water vapor is not used to transfer energy from one process operation to another or to introduce energy externally into the process. "Substantially Water Vapor-Free" means that the use of water vapor to transfer energy from one process operation to another or to introduce energy externally into the process is minimized so that the total amount of energy transfer using water vapor amounts to less than about 10%, less than about 20%, or less than about 30% of the net energy supplied. Water vapor used as a reactant, diluent, obtained as a product, or directly mixed with a process stream may be referred to as "process steam" and is not included in this definition.

[0026] Primary Energy Transfer Medium: A primary energy transfer medium can be a substance used to transfer energy in the form of heat energy from one process operation to another, or to introduce energy into a process. Note that a substance can serve multiple purposes in a process, such as acting as a reactant or reaction diluent while also acting as a medium to transfer heat from one process operation to another. In such cases, the use of water vapor as a reactant or diluent can be considered primary, and the effect of transferring heat can be considered secondary.

[0027] Resistive heating: Resistive heating can be heating by passing an electric current through a resistive unit.

[0028] Induction heating: Induction heating can be the process of heating an electrically conductive object (usually metal) by electromagnetic induction.

[0029] Radiation heating: Radiation heating can be the process of heating an object via radiation from one or more relatively hot objects.

[0030] External Combustion: External combustion can mean burning a fuel to generate heat and transferring this heat across a surface (e.g., a pipe wall) to the process fluid so that the combustion products do not mix with the process fluid.

[0031] Thermoelectric Device: A thermoelectric device may be a device for directly converting a temperature difference across a thermocouple into a voltage (or vice versa).

[0032] Isothermal operation: An isothermal operation can be an operation at a constant temperature. An isothermal operation can maintain the temperature within 0.5%, within 1%, within 2%, within 3%, within 4%, within 5%, or up to 10% of a given operating temperature.

[0033] Convective Heat Transfer: Convective heat transfer can be the transfer of heat from one place to another by the movement of one or more fluids.

[0034] Most of the above definitions are substantially as understood by those skilled in the art, however, for purposes of specific explanation of the subject matter of the present disclosure herein, one or more of the above definitions may be defined above in a manner different from the meaning ordinarily understood by those skilled in the art.

[0035] As used herein, references to when an IES is "available" include when an IES is obtainable and / or when an IES can be obtained at an economical price. That is, for brevity, "when an IES is available" is intended to include "when an IES is available and / or when it is economically desirable."

[0036] Figure 1 shows a schematic diagram of a typical conventional chemical process. The goal of this process is to convert feed A into product B, although several by-products (shown as stream C) are often also produced.

[0037] The unit operations used to carry out this conversion require significant amounts of energy. Traditionally, this energy is primarily provided by burning fuel, often natural gas, to generate heat, which is shown in Figure 1 as ΔH c (e.g., heat of combustion). This results in the undesirable production and emission of carbon dioxide (CO2). If the reaction is exothermic, additional energy is required as the heat of reaction, ΔH r If the reaction is endothermic, ΔH r An additional amount of energy equal to ΔH must be added. Some by-products are burned to produce energy (ΔH bp The total energy balance can also be affected if the process is carried out in a controlled manner (denoted as ). However, many chemical processes, even those involving exothermic reactions, are net energy consumers and require an external energy source (typically provided by a hydrocarbon fuel) to provide the net process energy.

[0038] Electricity is typically a small external input to most chemical manufacturing processes. Internal electrical requirements, such as for lighting or controls, are typically negligible, and for the few processes that require large amounts of electricity, such as electrochemical reactors (e.g., the chlor-alkali process for producing chlorine (Cl2) and sodium hydroxide (NaOH)), this electricity is typically generated within the plant boundary by the combustion of hydrocarbons; even if not generated within the plant boundary, if the electricity is obtained by the combustion of hydrocarbons rather than renewables, such use of electricity is comparable in terms of energy efficiency and CO2 emissions to on-site generation of electricity by hydrocarbon combustion.

[0039] In most chemical manufacturing processes, energy consumption can be conveniently divided into three major categories. In this first such broad category, referred to herein as Category C1, heat is provided directly as thermal energy by the combustion of fuel (e.g., natural gas / fossil fuel) in a furnace. (When utilized, "direct" here indicates the absence of an intermediate heat transfer medium such as steam.) These furnaces often operate at high temperatures, requiring large heat fluxes. The energy efficiency of such furnaces is limited by heat losses in the furnace flue gas. Even when these heat losses are minimized by cooling the flue gas to recover energy, e.g., to generate steam or to provide process heat, the conversion of the chemical energy contained in the fuel to usable thermal energy generally does not exceed 85-90%, even with substantial investment and loss of design and operational flexibility.

[0040] The second broad category of energy consumption in chemical processes, referred to herein as Category C2, involves the heating of various chemical streams, primarily to raise their temperature to desired reaction temperatures or to provide energy for separations, most commonly distillation. Some of this heat can be obtained through exchange with other chemical streams, but it is most typically provided by steam generated directly by the combustion of hydrocarbon fuels (e.g., natural gas / fossil fuels) or by heat transfer from flue gases from high-temperature furnaces (e.g., from Category C1). Modern chemical processes involve relatively complex steam systems (or other heat-transfer fluid systems, generally referred to herein for simplicity as steam heat transfer systems) to move energy from excess to needed locations. This steam system may include multiple pressure levels of steam to provide heat at various temperatures, as well as steam and condensate recovery systems, and is subject to corrosion, contamination, and other operational challenges, including water treatment and disposal of contaminated condensate. The proportion of energy contained in the steam that can be used to heat the process stream is generally limited to 90-95% due to practical constraints on heat transfer, steam condensation, and boiler water recirculation. If the steam is produced by a dedicated external boiler, as in the first category C1, an additional 10-15% or more is lost to the flue gas, so that up to 80-85% of the chemical energy contained in the fuel is used as heat by the chemical process.

[0041] The third major category of energy use in chemical processes, referred to herein as Category C3, is energy utilized to perform mechanical work. This work is primarily utilized to pressurize and move fluids from one location to another and is used to drive rotating equipment such as pumps, compressors, and fans. This Category C3 also includes refrigeration equipment, as it is primarily powered by compression. In most chemical facilities, the energy for this work is obtained by heat transfer from high-temperature process streams or, in Category C1 (e.g., convection sections), from partially cooled flue gas streams from furnaces, or by steam obtained directly from the combustion of hydrocarbons (e.g., natural gas / fossil fuels) in dedicated external boilers. Due to the limited conversion of thermal energy to mechanical work, the energy efficiency of these uses relative to the chemical energy content of the hydrocarbons used as fuel is low, typically only 25–40%.

[0042] It has been unexpectedly discovered that using electricity (e.g., renewable and / or non-renewable electricity) to replace energy derived from hydrocarbon fuels in chemical processes can improve the process by increasing overall energy efficiency while reducing carbon dioxide emissions. In some cases, using electricity (e.g., renewable and / or non-renewable electricity) to replace energy derived from hydrocarbon fuels in chemical processes can also improve reliability and operability, reduce emissions of, for example, NOx, SOx, CO and / or volatile organic compounds, and / or reduce production costs (e.g., when low-cost electricity is available).

[0043] According to aspects of the present disclosure, in the first category C1, heat traditionally provided as thermal energy by burning fuel (e.g., natural gas / fossil fuel) in a furnace and / or other heating is replaced with electrical heating. Electrical heating, electrical heating, generating heat electrically, electrical heater device, etc., refer to the conversion of electricity into usable thermal energy for application to a fluid. Such electrical heating includes, but is not limited to, heating by impedance (e.g., when electricity flows through a conduit carrying the fluid to be heated), ohmic heating, plasma, electric arc, radio frequency (RF), infrared (IR), UV, and / or microwave heating, heating by passing through a resistively heated element, heating by radiation from an electrically heated element, heating by induction (e.g., oscillating magnetic field), heating by electrically driven mechanical means (e.g., compression), heating via a heat pump, heating by passing a relatively hot inert gas or other medium through a tube containing the fluid to be heated, where the hot inert gas or other medium is electrically heated, or some combination thereof.

[0044] According to aspects of the present disclosure, the use of water vapor (or another heat transfer fluid) as in the second category C2 is excluded, and / or any water vapor (or other fluid) utilized solely as an intermediate heat transfer medium is generated or heated electrically (e.g., via electrical heating of water).

[0045] According to embodiments of the present disclosure, traditional rotating equipment (e.g., steam turbines) utilized in the third category C3 are replaced with electrically driven devices. According to embodiments of the present disclosure, the heat removal of the third category C3 is replaced with electrically driven heat removal, e.g., cooling and / or refrigeration. Terms such as electric cooling, electric cooler, electrically removing heat, electric cooling or refrigeration device, etc., refer to the removal of thermal energy from a fluid. Such electric cooling includes, but is not limited to, cooling by electrically driven devices. For example, but not limited to, electric cooling can be provided by powering a refrigeration cycle with electricity, where the refrigerant is compressed by an electrically driven compressor. As another example, electric cooling can be provided by powering a cooling fan that blows air, which cools a process fluid or element. In embodiments, electric heating and electric cooling can be provided by any power source.

[0046] FIG. 2 is a schematic diagram of a chemical process powered by renewable energy according to embodiments of the present disclosure. As shown in FIG. 2, a process powered by renewable energy may, in embodiments, appear similar to a conventional chemical process. However, some, most, or in some cases, substantially all of the fuel-supplied energy input may be replaced with renewable energy and / or renewable electricity. Such replacement of fuel input with non-carbon-based energy, renewable energy, and / or renewable electricity may, in embodiments, enable a significant reduction in CO2 emissions. In embodiments, any available form of renewable energy may be used. However, gains may be greatest when renewable electricity is utilized. Renewable energy may be obtained from, for example, without limitation, solar power, wind power, or hydroelectric power. Other types of renewable energy may also be applied to chemical plants according to embodiments of the present disclosure. For example, in embodiments, concentrated solar power, geothermal energy, and / or the use of direct solar thermal heating may be used to provide thermal energy and reduce CO2 emissions.

[0047] One of the primary benefits of providing required energy via (e.g., renewable) electricity can be improved process energy efficiency. Table 1 shows the energy efficiencies of unit operations, illustrating the three categories of energy use in a chemical plant, identified above as C1, C2, and C3. Table 1 shows that using electricity increases the efficiency of each of the three categories of energy consumption. According to embodiments of the present disclosure, gains can be greatest when steam drives for rotating equipment are replaced with electric motors (as in the third category C3 above), which can operate at three times the energy efficiency of steam drives. These gains are only realized if the electricity is obtained from a non-carbon-based renewable source, since generating electricity from carbon-based fuel combustion is only 30–45% energy efficient. Using renewable electricity for heating applications (as in the first category C1 and second category C2 above) results in smaller, but still significant, gains. The net result is that using renewable energy instead of carbon-based fuels (e.g., natural gas or other hydrocarbons) results in less total energy used.

[0048] (Table 1) Energy efficiency of unit operations TIFF2026016473000002.tif49130

[0049] According to the present disclosure, in categories C1, C2, and / or C3 above, non-carbon-based energy, renewable energy, and / or electricity (e.g., from renewable and / or non-renewable sources) can be utilized rather than traditional energy sources. In embodiments, electrification is utilized for most or substantially all of the equipment. In embodiments, electrification is utilized for most or substantially all of the unit operations. In embodiments, electrification is utilized for most or substantially all of the equipment and unit operations. In embodiments, electrification is utilized for most or substantially all of the process applications, engines, cooling and / or heating (e.g., electrically driven heat pumps, refrigeration, electric heating), radiant, storage systems, or combinations thereof.

[0050] In embodiments, non-carbon-based and / or renewable energy sources include wind, solar, geothermal, hydroelectric, nuclear, tidal, wave, ocean thermal gradient power, osmotic power, or a combination thereof. In embodiments, non-carbon-based energy sources include hydrogen. In embodiments, electricity for electrification described herein is generated from such renewable and / or non-carbon-based energy sources. In embodiments, some or all of the electricity is from a non-renewable and / or carbon-based source, such as, but not limited to, hydrocarbons (e.g., renewable or non-renewable hydrocarbons), coal, or the combustion of hydrogen derived from hydrocarbons (e.g., renewable or non-renewable hydrocarbons).

[0051] The majority of CO2 emissions from most chemical plants are the result of burning fossil fuels to power the plants. An additional benefit of using renewable energy in chemical synthesis according to embodiments of the present disclosure is that the amount of greenhouse gases emitted is significantly reduced (e.g., by at least 5% or more, at least 10% or more, at least 20% or more, at least 30% or more, at least 40% or more, at least 50% or more, at least 60% or more, at least 70% or more, at least 80% or more, at least 90% or more, or at least 100% or more) compared to comparable conventional chemical synthesis plants or processes in which hydrocarbons and / or fossil fuels may be burned. Burning hydrocarbons (e.g., natural gas, methane) to generate energy produces carbon dioxide (CO2). This production can be reduced or avoided by using renewable energy according to embodiments of the present disclosure. In embodiments of the present disclosure, the amount of CO produced per ton of product produced is reduced to about 1.6 tonnes or less, about 1.5 tonnes or less, about 1.4 tonnes or less, about 1.3 tonnes or less, about 1.2 tonnes or less, about 1.1 tonnes or less, about 1.0 tonnes or less, about 0.75 tonnes or less, about 0.5 tonnes or less, about 0.30 tonnes or less, about 0.25 tonnes or less, about 0.2 tonnes or less, about 0.1 tonnes or less, about 0.05 tonnes or less, or about 0 tonnes or less of CO per ton of chemical product. Additionally, in embodiments of the present disclosure, the use of renewable energy allows those hydrocarbons (e.g., natural gas, methane) that would typically be burned for fuel to be utilized for use as chemical feedstocks (e.g., to produce methanol), an increased value application.

[0052] The use of renewable electricity in chemical production can also provide operational advantages. For example, in embodiments, electrical power can be used to provide more precise and adjustable heat input, for example, to control the temperature profile along a reactor or to change the temperature of specific trays in a distillation column. In embodiments, the use of electric heating in a reaction section (e.g., a pyrolysis reaction section) can provide better control and / or faster decoking. Without limitation, other examples include the use of electrically powered refrigeration units to improve separation efficiency, and the use of fast-acting, on-demand electric heaters and steam generators to replace inefficient standby gas-fired boilers for other facility uses. The use of electricity can also enable significant operational advantages during startup or shutdown or to accommodate process variations. In general, electricity as an energy source can be applied in precise and adjustable amounts to specific locations in rapid response to process changes, providing various advantages over the use of thermal / combustion energy.

[0053] Additionally, the use of renewable electricity according to aspects of the present disclosure can improve the energy efficiency of facilities that supply energy to multiple chemical plants (e.g., an olefin synthesis plant and an adjacent ammonia synthesis plant, or an olefin synthesis plant and an adjacent methanol synthesis plant). For example, if the compressor in an air separation unit that supplies oxygen and nitrogen to several different production facilities is powered by renewable electricity, a significant energy gain can be achieved compared to supplying this power with steam obtained from the combustion of natural gas.

[0054] Energy recovery may be provided, in embodiments, via a high-temperature heat pump or steam recompression. The plant may further include heat and / or energy storage, for example, for use when intermittent energy sources (IES) are utilized. In embodiments, waste heat can be raised to a usable temperature level via an electrically driven heat pump. In other embodiments, energy can be recovered as electricity when the pressure of the process stream is reduced by using a power-generating turbine instead of a control valve. In other embodiments, energy can be recovered as electricity using a thermoelectric device.

[0055] According to embodiments of the present disclosure, the use of renewable electricity to replace natural gas or other hydrocarbons as an energy source can be done as part of a retrofit of an existing chemical process (e.g., an existing methanol, ammonia, or olefin synthesis plant) or as an integral component of the design of a new chemical plant (e.g., a new methanol, ammonia, or olefin synthesis plant). In a retrofit, the opportunity to use renewable energy may depend on elements of the existing design, such as the steam system. In a retrofit, careful examination of the energy balance and the entire steam system is required, as electrifying individual equipment regardless of these considerations can result in energy inefficiencies. In embodiments, as seen in Table 1, the highest efficiency gains are achieved by replacing steam drives for rotating equipment (e.g., in the third category C3) with electric motors. However, different objectives may lead to different choices for partial electrification. In embodiments, in some cases, relatively large CO2 reductions may be realized by first replacing hydrocarbon-fired furnaces (e.g., in the first category C1) at the expense of relatively small gains in energy efficiency. In embodiments, when thermal energy and / or steam are obtained from multiple hydrocarbon sources, the most advantageous operation can be achieved by first eliminating the most expensive and / or polluting fuel sources. The extent to which renewable energy can be included and the extent to which existing fuel consumption and carbon dioxide (CO2) emissions can be reduced can vary depending on the application and would be within the skill of one of ordinary skill in the art upon reading this disclosure.

[0056] In embodiments, planning for the use of renewable energy in the design of fundamental chemical facilities (e.g., fundamental methanol, ammonia, or olefin synthesis plants) can further increase opportunities for greater energy efficiency and lower CO2 emissions. In embodiments, powering all rotating equipment with electricity (e.g., third category C3) is utilized to achieve significant improvements in energy efficiency. In embodiments, substantially all (or most, or more than 40%, 50%, 60%, 70%, 80%, or 90%) electric heating (e.g., first category C1 and / or second category C2) is utilized, substantially reducing or even avoiding inefficiencies due to flue gas heat losses. In embodiments, the use of steam generated via the combustion of fossil fuels (e.g., second category C2) can be minimized or avoided entirely. In embodiments, catalyst changes and / or reactor operating conditions can be utilized to generate less heat in the reactor and / or generate less combusted by-products. In embodiments, because the use of renewable electricity according to the present disclosure alters the relative costs of compression and refrigeration, plant (e.g., methanol, ammonia, or olefins synthesis plants) designs based on the use of renewable electricity can improve the optimization of separation operations. Such improved separation can also, in embodiments, further capture minor by-products from vent streams and leverage these minor products for further use as feedstocks or products. Furthermore, the use of low-cost electricity according to embodiments of the present disclosure can enable the introduction of novel technologies such as, but not limited to, hybrid gas and electric heaters, variable speed compressor drives, distributed refrigeration, heat pumps, improved distillation columns, passive solar heating of fluids, precise control of reactor temperature profiles, new materials of construction, and quenching or cooling using electrically refrigerated diluents. If the cost of electricity is sufficiently low, the use of electricity as taught herein can favor the introduction of new electrochemical processes. For new builds, for example, it may be less capital intensive to drive the process electrically due to the lack of a (e.g., plant-wide) steam distribution system.

[0057] According to embodiments of the present disclosure, non-carbon-based energy, renewable energy, and / or electricity (renewable, non-renewable, carbon-based, and / or non-carbon-based electricity) can be used to produce nearly any chemical, including, but not limited to, methanol, ammonia, olefins (e.g., ethylene, propylene), aromatics, and polymers. Non-carbon-based energy, renewable energy, and / or electricity can also be used, in embodiments, to prepare feedstocks for chemical and fuel production, for example, MTBE synthesis, cracking, isomerization, and reforming. In such embodiments, as described above, some (e.g., at least about 10, at least about 20, at least about 30, at least about 40, or at least about 50%), a majority (e.g., at least about 50, at least about 60, at least about 70, at least about 80, at least about 90, or at least about 95%), or all (e.g., about 100%) of the heating of the entire plant / process or section thereof may be provided by electric heating, and / or some (e.g., at least about 10, at least about 20, at least about 30, at least about 40, or at least about 50%), a majority (e.g., at least about 50, at least about 60, at least about 70, at least about 80, at least about 90, or at least about 95%), or all (e.g., about 100%) of the cooling of the entire plant / process or section thereof may be provided by electric cooling.

[0058] A generalized chemical synthesis plant operated by an IES according to an embodiment of the present disclosure will now be described with reference to FIG. 3, which is a schematic diagram of a chemical synthesis plant I utilized to produce at least one chemical product 35 according to an embodiment of the present disclosure. Without limitation, in certain embodiments, the at least one chemical product includes chemicals produced as described, for example, in U.S. Provisional Patent Application No. 62 / 792,631, U.S. Provisional Patent Application No. 62 / 792,632, U.S. Provisional Patent Application No. 62 / 792,633, U.S. Provisional Patent Application No. 62 / 792,634, and U.S. Provisional Patent Application No. 62 / 792,635, filed January 15, 2019, and entitled "Use of Renewable Energy in the Production of Chemicals," or U.S. Provisional Patent Application No. 62 / 792,636 and U.S. Provisional Patent Application No. 62 / 792,637, entitled "Use of Intermittent Energy in the Production of Chemicals," the disclosures of each of which are incorporated herein for any purpose not contrary to this disclosure. Without limitation, in certain embodiments, the at least one chemical product may be, for example, ethylene produced by cracking in one or more cracking reactors (e.g., via olefin synthesis as described in U.S. Provisional Patent Application Nos. 62 / 792,612 and 62 / 792,615, filed January 15, 2019, entitled "Use of Renewable Energy in Olefin Synthesis," the disclosures of each of which are incorporated herein for any purpose not contrary to this disclosure); ammonia produced in one or more ammonia synthesis reactors (e.g., via ammonia synthesis as described in U.S. Provisional Patent Application Nos. 62 / 792,617 and 62 / 792,619, filed January 15, 2019, entitled "Use of Renewable Energy in Ammonia Synthesis," the disclosures of each of which are incorporated herein for any purpose not contrary to this disclosure);For example, methanol produced in one or more methanol synthesis reactors (e.g., via the methanol synthesis described in U.S. Provisional Patent Application Nos. 62 / 792,622 and 62 / 792,627, filed January 15, 2019, entitled "Use of Renewable Energy in Methanol Synthesis," the disclosures of each of which are incorporated herein for any purpose not inconsistent with this disclosure); propylene produced, for example, by cracking; ethylene oxide produced, for example, by oxidation of ethylene; monoethylene glycol produced, for example, by hydration of ethylene oxide; ethylene dichloride produced, for example, by chlorination of ethylene; vinyl chloride produced, for example, from ethylene dichloride; α-olefins produced, for example, by oligomerization; olefins produced, for example, by dehydrogenation of paraffins; isoparaffins produced, for example, by isomerization of normal paraffins (e.g., isobutane produced from n-butane); aromatics (BT) produced, for example, from paraffins and / or naphthenes by cyclization and / or dehydrogenation. X); aromatics, for example, produced from naphtha by cyclization and / or dehydrogenation; ethylbenzene, for example, produced by alkylating benzene with ethylene; styrene, for example, produced by dehydrogenating ethylbenzene; cumene, for example, produced by alkylating benzene with propylene; phenol, for example, produced by oxidizing cumene; terephthalic acid, for example, produced by oxidizing paraxylene; oxygen, for example, produced by separation from air; nitrogen, for example, produced by separation from air; MTBE, for example, produced by etherification of isobutylene; polyethylene, polypropylene, polyvinyl chloride, polystyrene, polycarbonate, and / or polyethylene terephthalate (PE, PP, PVC, PS, PC, PET), for example, produced by polymerization. In other specific embodiments, the at least one chemical product includes, but is not limited to, acetic acid, for example, produced by carbonylating methanol; vinyl acetate, for example, produced by reacting acetic acid with ethylene;For example, propylene produced by the oligomerization of methanol (commonly known as the methanol to olefins process); acrylic acid produced by the oxidation of propylene; methacrolein produced by the oxidation of isobutylene; methyl methacrylate produced by the oxidation of methacrolein; acrylonitrile produced by the ammoxidation of propylene; sulfuric acid produced by the oxidation of sulfur; nitric acid produced by the oxidation of ammonia; propylene glycol produced by the hydration of propylene; one or more nylon precursors selected from adipic acid, caprolactam, cyclohexanone, 1,6 diaminohexane, or combinations thereof; or polyvinyl alcohol (PVA), polyacrylate, polymethyl methacrylate (PMMA), nylon;

[0059] The present disclosure relates to a chemical synthesis plant for producing chemical products, wherein a majority of the net energy required by one or more sections, units, or groups of like units or unit operations of the chemical synthesis plant is derived from intermittent energy sources (e.g., non-carbon-based energy sources (e.g., not produced by combustion of carbon-based fuels such as hydrocarbons), renewable energy (e.g., non-fossil fuel derived energy (E NF ) or non-carbon energy from electricity and / or renewable electricity (E NC The present invention describes a chemical synthesis plant, wherein the chemical synthesis plant is configured / operable to be supplied by intermittent energy, including NC Source or E NF The source may, in embodiments, comprise, primarily comprise, consist essentially of, or consist of electricity. NC Source or E NFThe source can comprise, primarily comprise, consist essentially of, or consist of renewable electricity. In embodiments, a portion (e.g., about 5 or more, about 10 or more, about 20 or more, about 30 or more, about 40 or more, about 50 or more), a majority (e.g., about 50% or more, about 60% or more, about 70% or more, about 80% or more, about 90% or more, or about 95% or more), or all (e.g., about 100%) of the net energy required by an entire chemical synthesis plant, a section of the plant (e.g., a feed pretreatment section, a reaction section, and / or a product purification section), a group of similar units (e.g., compressors, power supply units, heating units, reboilers, cooling units, refrigeration units, separators, reactors, distillation / fractionation columns), or unit operations of the plant (e.g., compression, power supply, heating operations, cooling operations, reactions, separations), or combinations thereof, can be generated from electricity, renewable energy (e.g., non-fossil fuel-derived energy (E NF )) and / or non-carbon-based energy (E NC ). In embodiments, electricity is supplied from renewable intermittent energy sources, such as, without limitation, wind (e.g., via wind turbines) or solar (e.g., sunlight via photovoltaic (PV) panels). In embodiments, electricity is supplied by an entire chemical synthesis plant, a section of the plant (e.g., a feed pretreatment section, a reaction section, and / or a product purification section), a unit, or a group of similar units (e.g., compressors, power supply units, heating units, reboilers, cooling units, refrigeration units, reactors, separators, distillation / fractionation columns), or unit operations (e.g., compression, power supply, separation, heating, cooling, reaction) of a chemical synthesis plant, or combinations thereof, that is required by a chemical synthesis plant, a renewable energy (e.g., non-fossil fuel derived energy (E2), or a combination thereof, that is traditionally supplied to similar chemical synthesis plants via the combustion of fuels, carbon-based fuels, and / or fossil fuels, and / or the use of steam (e.g., itself produced by the combustion of such fuels) as an intermediate heat (and / or energy) transfer fluid. NF ) and / or non-carbon-based energy (E NC) is supplied without burning fuels, carbon-based fuels, and / or fossil fuels, and / or without using steam produced by combustion of such fuels as an intermediate heat (and / or energy) transfer fluid. In embodiments, the net energy of the entire plant, or one or more sections, units, or groups of similar units of the plant, is supplied by electricity from intermittent renewable energy sources. In embodiments, energy is supplied by electricity from intermittent renewable energy sources when renewable IES are available (e.g., in operation or in storage) or below a threshold price. For example, in embodiments, heating is provided electrically via resistance heating, and electricity is obtained primarily from IES when available or below a threshold price. The available intermittent energy can include "on-the-run" energy provided directly through the IES (e.g., via solar cells) and stored energy obtained from the IES during operation and utilized later within the plant.

[0060] In embodiments, chemical synthesis plants of the present disclosure are configured such that a majority (e.g., greater than 50%, 60%, 70%, 80%, or 90%) of the net energy required for powering, heating, cooling, compression, separation, or combinations thereof utilized via a feed pretreatment system, one or more reactors, a product purification system, or combinations thereof, is supplied by electricity. In embodiments, the electricity is supplied from an IES when the IES is available or below a threshold price.

[0061] In embodiments, chemical synthesis plants according to embodiments of the present disclosure are large plants having a production capacity of about 10,000 tons per year or more, about 100,000 tons per year or more, about 250,000 tons per year or more, about 500,000 tons per year or more, or about 10,000,000 tons per year or more of a desired chemical product. At the sizes anticipated in this disclosure, the amount of energy provided by the IES is correspondingly large. In embodiments, a partially or fully electrified plant according to the methods of the present disclosure consumes at least (i.e., equal to or greater than) about 10 MW, at least about 15 MW, at least about 20 MW, at least about 25 MW, at least about 50 MW, at least about 100 MW, at least about 150 MW, at least about 200 MW, at least about 300 MW, at least about 400 MW, at least about 500 MW, at least about 750 MW, or at least about 1000 MW of electricity from the IES.

[0062] As disclosed herein, certain embodiments of a chemical synthesis plant are used to illustrate the electrification of a chemical synthesis plant by an IES; however, it should be understood that numerous arrangements of units and a variety of chemical synthesis technologies can be electrified in accordance with the present disclosure, as will be apparent to those skilled in the art upon reading the description herein.

[0063] Referring to Figure 3, which is an overview of a generalized chemical synthesis plant I, the chemical synthesis plant may be considered to include one or more of the following process sections for converting a feed stream 5 containing one or more reactants into a chemical product stream 35 (and optionally one or more by-product streams 31): a feed pre-treatment section 10, a reaction (or primary reaction) section 20, a product purification section 30, or a combination thereof. Other sections, such as a recycle section, an energy (e.g., electricity) generation and / or energy storage (e.g., hydrogen storage) section, are also within the scope of the present disclosure. Such sections are briefly described in the next few paragraphs and in more detail below.

[0064] As shown in the chemical synthesis diagram of FIG. 3 , a feed pre-treatment section 10 of a chemical synthesis plant is operable to prepare a reactant feed 5 for reaction (e.g., remove undesirable components (e.g., sulfur) from the feed and adjust the temperature and / or pressure of the feed) to provide a pre-treated feed 15. In applications, the chemical synthesis plant of the present disclosure does not include a feed pre-treatment section. A reaction or “chemical synthesis” section 20 is operable to produce a desired chemical product from the pre-treated feed 15, thereby providing a crude chemical product stream 25. A product purification section 30 is operable to separate a purified chemical product 35 from the crude chemical product stream 25. In applications, the chemical synthesis plant of the present disclosure does not include a product purification section.

[0065] As shown in FIG. 3 and described above, the energy (E) input (conventionally, carbon-based energy (E) from a carbon-based energy source) to or within a chemical synthesis plant, or one or more sections or groups of units, similar units, or unit operations thereof, is C ) 2A, Fossil fuel-derived energy from fossil fuel-based energy sources (E F ) 3A or through a heat or energy transfer medium (S HT )1) can be provided solely or primarily through the use of steam (e.g., steam generated for this purpose using energy obtained from a carbon-based energy source or a fossil fuel-based energy source) from a non-carbon-based energy source (E NC ) 2B, Renewable / Non-Fossil Energy from Renewable Intermittent Sources (E NF ) 3B, and / or electricity (e.g., intermittent electricity and / or renewable intermittent electricity). C )2A, Fossil fuel-derived energy (E F) 3A, or both, can be partially or completely replaced by electricity. In embodiments, the electricity may be obtained from non-carbon-based fuels, renewable fuels, renewable energy sources, or combinations thereof. A benefit obtained via the systems and methods disclosed herein can be a reduction in greenhouse gas (GHG) emissions from a chemical synthesis plant or process. In embodiments, the elimination or reduction of steam systems can also lower capital and operating costs.

[0066] As described above and shown in FIG. 3, the energy (E) input (traditionally, carbon-based energy (E)) to or within a chemical synthesis plant, or one or more sections or groups of units, similar units, or unit operations thereof, is C ) sources, non-renewable energy sources, non-electrical energy sources, or through a heat or energy transfer medium (S HT ) can be provided solely or primarily through the use of steam and / or through the use of steam generated by the combustion of non-renewable fuels, as non-carbon-based energy (E NC ) sources, renewable energy sources, e.g., intermittent renewable electricity, electricity (from any source), or by energy from a heat or energy transfer medium (S HT The system and method disclosed herein may be used to partially or completely replace steam generated solely or primarily as a catalyst and / or steam generated by combustion of fuel. A benefit obtained through the systems and methods disclosed herein may be a reduction in greenhouse gas (GHG) emissions from a chemical synthesis plant or process.

[0067] Although not intending to be limited by the examples provided herein, some descriptions of how chemical synthesis plants can be electrified using IESs in accordance with embodiments of the present disclosure are provided herein with reference to exemplary chemical synthesis plant I in Figure 3. In various embodiments, the described steps, sections, groups of units, or unit operations may be present or operated in any suitable order, one or more of the steps, sections, units, or unit operations may be absent, repeated, or replaced by a different step, section, unit, or unit operation, or additional steps, sections, units, or unit operations not described herein may be used. Furthermore, although a step is described as being within a particular section, the step may also be considered part of another section.

[0068] As noted above, in embodiments, the chemical synthesis plant of the present disclosure comprises a feed pre-treatment section 10. Such a feed pre-treatment section 10 may be operable to remove one or more components, such as, without limitation, catalyst poisons, from the feed(s), adjust the pressure of the feed(s) to a desired operating pressure in the downstream (e.g., reaction) section 20, adjust the temperature of the feed(s) to a desired operating temperature, and / or otherwise modify the feed(s) prior to the downstream (e.g., reaction) section 20.

[0069] As noted above, in embodiments, the disclosed chemical synthesis plant includes a chemical synthesis section 20. Such a chemical synthesis section 20 may be operable to produce a desired chemical (or multiple desired chemicals) from a feed 5 or a pretreated feed 15. Producing the desired chemical may include maintaining one or more reactors at a desired temperature / temperature profile and / or pressure to provide a crude chemical product 25, providing additional components (e.g., diluent, catalyst) of a desired composition, temperature, and / or pressure to the one or more reactors, extracting the chemical product from the one or more reactors, etc. The one or more reactors may be configured to operate in series or parallel, and one or more chemical reactions may occur in either series or parallel. The reactions that occur may be endothermic, exothermic, or thermoneutral in nature, and the net of all reactions that occur may be endothermic, exothermic, or thermoneutral in nature.

[0070] As noted above, in embodiments, the chemical synthesis plant of the present disclosure may include a product purification section 30. Such product purification section 30 may be operable to separate the chemical product or products and by-products from the crude chemical product in any number of ways. For example, separation may occur via one or more distillation columns and associated reboilers, flash separators, solvent extractors, extractive distillation units, crystallizers, evaporators, phase separators (e.g., decanters, cyclones, etc.), absorbers, adsorber, membranes, etc., to provide a chemical product stream 35.

[0071] As shown in FIG. 3 , in embodiments, a majority, greater than 20%, greater than 30%, greater than 40%, greater than 50%, greater than 60%, greater than 70%, greater than 80%, or greater than 90%, or substantially all, of the net energy required within the chemical synthesis plant or one or more sections thereof (e.g., energy E1 required within feed pretreatment section 10, energy E2 required within reaction section 20, and / or energy E3 required within product purification section 30) [or, as described below, within one or more units, or groups of units (e.g., compressors, separators, distillation columns), or unit operations (e.g., compression, power supply, separation, heating, cooling)] is supplied from non-carbon-based energy sources, from renewable energy sources such as renewable electricity, or from electricity (from any source, renewable and / or non-renewable). In embodiments, a majority, greater than 20%, greater than 30%, greater than 40%, greater than 50%, greater than 60%, greater than 70%, greater than 80%, or greater than 90%, or substantially all, of the net energy required within a chemical synthesis plant or one or more sections thereof (e.g., E=E1+E2+E3) (e.g., the energy E1 required within feed pretreatment section 10, the energy E2 required within reaction section 20, and / or the energy E3 required within product purification section 30) [or, as described below, within one or more units, or groups of units (e.g., compressors, separators, distillation columns), or unit operations (e.g., compression, power supply, separation, heating, cooling)] is provided without burning fuel and / or without generating steam alone or at all as a heat (and / or energy) transfer medium.

[0072] In embodiments, a majority, greater than 20%, greater than 30%, greater than 40%, greater than 50%, greater than 60%, greater than 70%, greater than 80%, or greater than 90%, or substantially all, of the net energy required by one or more units, or groups of units, or unit operations is supplied from non-carbon-based energy sources, from renewable energy sources such as renewable electricity, and / or from electricity (from any source, renewable and / or non-renewable). For example, and without limitation, in embodiments, such units include compressors (e.g., feed compressors and / or refrigeration compressors), pumps, separators (e.g., distillation columns, absorption units and / or strippers), extractors (e.g., for liquid-liquid extraction and / or extractive distillation), reactors for specific reactions (e.g., individual reactors or multiple reactors in series and / or parallel), heaters (e.g., heat exchangers and / or reboilers), coolers (e.g., refrigeration and / or cryogenic units, blowers, cooling water systems), equipment for regeneration (e.g., for catalyst, adsorber or stripping solution regeneration), or combinations thereof.

[0073] In embodiments, a majority, greater than 20%, greater than 30%, greater than 40%, greater than 50%, greater than 60%, greater than 70%, greater than 80%, or greater than 90%, or substantially all, of the net energy required for a series of operations (e.g., compressing, pumping, powering, mixing, separating, heating, cooling, reacting, recycling, energy storage, and / or energy generation) is supplied from non-carbon-based energy sources, from renewable energy sources such as renewable electricity, or from electricity (from any source, renewable and / or non-renewable).

[0074] A significant portion of the energy (E) used in chemical plants is used for heating and cooling (Q). Because of its importance, any portion of net energy transferred as heating and cooling can be considered separately. As noted above, in embodiments, a majority, greater than 20%, greater than 30%, greater than 40%, greater than 50%, greater than 60%, greater than 70%, greater than 80%, or greater than 90%, or substantially all, of the net energy required for heating and / or cooling is supplied from non-carbon-based energy sources, from renewable energy sources such as renewable electricity, and / or from electricity (from any source, renewable and / or non-renewable). For example, in embodiments, a majority, greater than 20%, greater than 30%, greater than 40%, greater than 50%, greater than 60%, greater than 70%, greater than 80%, or greater than 90%, or substantially all, of the net heat input or removal required within a chemical synthesis plant or one or more sections thereof (e.g., heat input or removal Q1 required within feed pretreatment section 10, heat input or removal Q2 required within reaction section 20, and / or heat input or removal Q3 required within product purification section 30) and provided by one or more units or groups of units (e.g., refrigeration units, heat exchangers) is provided from non-carbon-based energy sources, from renewable energy sources such as renewable electricity, and / or from electricity (from any source, renewable and / or non-renewable). According to the present disclosure, when cooling a process stream, as much heat as possible should be used to heat other process streams. However, below a certain temperature, additional heat transfer is no longer effective or useful, and blowers, cooling water, and / or refrigeration (which require energy input for heat removal) are utilized. In embodiments, for example, heat exchangers, refrigeration units, or combinations thereof for varying the temperature of a process stream may be electrically powered. In embodiments, the refrigeration units include one or more electrically driven compressors. In embodiments, steam is not utilized solely as an intermediate heat and / or energy transfer stream, and the plant or section thereof does not include a complex steam system as traditionally used for energy transfer. In embodiments, steam is used as a heat transfer fluid and is not used to perform mechanical work, for example, to drive a pump or compressor.In embodiments, the heating is provided by resistive heating. In embodiments, the heating is provided by inductive heating. In embodiments, the heating is provided electrically to radiant panels, which then transfer heat to the process by radiation.

[0075] In embodiments, reactors in reaction section 20 or elsewhere that may traditionally be heated by burning fuel may be heated without burning fuel (and thus without the simultaneous production of corresponding flue gas) according to embodiments of the present disclosure. For example, reactors may be electrically heated in embodiments. In this manner, greenhouse gas emissions from the plant may be reduced, and in some cases, hydrocarbons traditionally burned as fuel in reaction section 20 (or elsewhere) may be utilized to generate additional chemical products within the plant or in a different chemical production plant. In embodiments, the elimination of flue gas improves energy efficiency because the loss of heat contained in the flue gas to the atmosphere is eliminated. By utilizing electrical heating of the reactor, embodiments may improve the temperature profile along the reaction zone or reactor. For example, it may be possible to provide a desired heat flux along the length of the reactor, improve temperature control for the reaction, shift equilibria, and / or minimize coking and / or catalyst deactivation.

[0076] In embodiments, one or more reactors, feed preparation systems, product purification systems, or combinations thereof produce a lights stream (e.g., flue gas, purge gas, or tail gas), and the lights stream, reactants utilized in one or more reactors, or combinations thereof, comprise components selected from hydrogen, carbon monoxide, one or more light hydrocarbons (e.g., C1 hydrocarbons, C2 hydrocarbons, C3 hydrocarbons, and / or C4 hydrocarbons), or combinations thereof, and the chemical synthesis plant of the present disclosure is not configured to combust the lights stream, its components, or both, as fuel. In embodiments, the energy of such combustion is replaced with electricity.

[0077] In embodiments, electricity can be utilized to produce cooler cooling water (e.g., 2, 5, 10, or 15° C. cooler) than conventionally used to enhance downstream operations. In embodiments, electricity can be used in operations to improve the quality of water used for cooling water, for example, by removing contaminants. In embodiments, electricity can be used to heat gas or liquid streams used to regenerate catalysts, adsorbents, or absorption solutions, for example, steam stripping the adsorbent to regenerate the adsorbent. In embodiments, electricity can be used to regenerate amine absorption solutions. In embodiments, electricity can be used to preheat gases used in reactions. In embodiments, electricity can be used to vaporize feeds and / or diluents, for example, without limitation, steam or naphtha. In embodiments, electricity can be used to heat tracing lines or vessels to maintain gases and / or liquids at desired temperatures during storage and / or transmission where the gases and / or liquids would otherwise be cooled. In embodiments, electricity can be used to power thermoelectric devices and / or heat pumps to enable simultaneous heating and cooling. In embodiments, electricity can be used to provide "trim heating," where a gas or liquid stream that has been preheated by heat transfer from a hot reaction product stream (via a feed / product exchanger) is further heated before the stream is fed to a reactor or other downstream equipment. In embodiments, electrically powered heaters may be used to preheat reactants or other process streams when starting up a plant, but without limitation, electricity can be used to provide "start-up" heating to a process that is no longer utilized during plant operation as other heat sources, such as a hot reactor product stream, become available.

[0078] As noted above, in embodiments, a majority, greater than 20%, greater than 30%, greater than 40%, greater than 50%, greater than 60%, greater than 70%, greater than 80%, or greater than 90%, or substantially all, of the net energy required for compression within the chemical synthesis plant or one or more sections thereof (e.g., feed pretreatment section 10, reaction section 20, and / or product purification section 30) is supplied from non-carbon-based energy sources, from renewable energy sources such as renewable electricity, and / or from electricity (from any source, renewable and / or non-renewable). Such compression may be utilized, for example, to increase the pressure of the feed 5 within pretreatment section 10, to increase the pressure of a stream within reaction section 20, to increase the pressure of a stream within product purification section 30, and / or to increase the pressure of a recycle stream.

[0079] For example, according to embodiments of the present disclosure, compression may occur via an electric motor-driven compressor rather than via a turbine driven by gas / fuel combustion or via a turbine powered by steam generated from hydrocarbon combustion. In embodiments, the compressor is operated by a turbine driven by steam generated by electrical heating. For example, electric motors and / or turbines driven by electrically generated steam may be utilized to provide compression throughout a chemical synthesis plant or one or more sections thereof, or for one or more operations (e.g., refrigeration). In embodiments, a majority, greater than 20%, greater than 30%, greater than 40%, greater than 50%, greater than 60%, greater than 70%, greater than 80%, or greater than 90%, or substantially all, of the compressors or operations (e.g., stream compression, cooling, refrigeration) within one or more sections of a chemical plant, or a group of similar units (e.g., refrigeration units), utilize electric motor-driven compressors and / or turbines driven by electrically generated steam.

[0080] In embodiments, high pressure flow within the plant is utilized to generate electricity for use within one or more sections of the chemical synthesis plant. For example, in embodiments, the pressure reduction step within the chemical synthesis plant or one or more sections thereof may be via a turbine rather than a control valve.

[0081] In embodiments, steam generated by combustion of fuel or generated solely for heat and / or energy transfer is not utilized in the chemical synthesis plants and methods of the present disclosure (e.g., in the pretreatment section 10, reaction section 20, and / or product purification section 30). Thus, chemical synthesis plants according to the present disclosure, in embodiments, can be operated without complex steam heat and / or energy transfer systems (which may be conventionally utilized in chemical plants for producing the same chemicals). In some applications, for example, when steam is utilized in reactors as a feed component and / or diluent, such steam may be generated by heat transfer with process streams within the chemical synthesis plant and / or may be generated electrically. In embodiments, steam generated via heat transfer with process streams may be superheated using electricity. In embodiments, electrical superheating of low-temperature steam allows for improved heat and energy recovery. In embodiments, steam is not utilized as a commodity or facility throughout the chemical synthesis plant. In embodiments, chemical synthesis plants of the present disclosure are essentially free of water vapor or utilize substantially less water vapor (e.g., use at least 10, at least 20, at least 30, at least 40, at least 50, at least 60, at least 70, at least 80, at least 90, or at least 100 volume percent (vol%) less water vapor) than conventional plants for producing the same chemicals. For example, conventional plants for producing the same chemicals may utilize water vapor generation for reboilers of distillation columns in feed pre-treatment section 10 and / or product purification section 30, may utilize water vapor generation to drive steam turbines for compression processes and / or recycle streams, or may utilize water vapor generation to drive steam turbines for refrigeration. In embodiments, no water vapor is generated for these operations in chemical plants according to the present disclosure, or substantially less water vapor (e.g., at least 10, at least 20, at least 30, at least 40, at least 50, at least 60, at least 70, at least 80, at least 90, or at least 100 volume percent (vol%) less water vapor) is generated.In embodiments, steam is used as a heat transfer fluid but is not used to perform mechanical work (e.g., to drive a compressor or pump). In embodiments, steam generated for these operations is primarily (e.g., the largest percentage of total steam utilized is electrically generated), primarily (e.g., more than 50% of the steam is electrically generated), or substantially entirely generated electrically. In embodiments, steam utilized as a reactant or diluent is primarily (e.g., the largest percentage of total steam utilized is electrically generated), primarily (e.g., more than 50% of the steam is electrically generated), or substantially entirely generated electrically. In embodiments, steam utilized as a reactant and / or diluent is generated using resistive heating. In embodiments, steam utilized as a reactant and / or diluent is generated using an electrode boiler or electric immersion heater. In embodiments, steam is superheated using electricity.

[0082] In embodiments, in chemical synthesis plants or processes of the present disclosure, a relatively large amount of energy is utilized directly "as is," e.g., by utilizing heat from a hot product effluent stream to heat a feed stream, rather than being converted via, e.g., steam generation and conversion of thermal energy to mechanical energy via a steam turbine. According to embodiments of the present disclosure, direct use of energy can increase the energy efficiency of a chemical synthesis plant, e.g., by reducing energy efficiency losses incurred when heat is converted to mechanical energy and / or via flue gases.

[0083] In embodiments, electricity can be used to provide motive force to fluids. For example, electricity can be used to power pumps to move and / or pressurize liquids and / or power blowers and / or fans. In embodiments, some, most, or all (e.g., 20, 30, 40, 50, 60, 70, 80, 90, or 100%) of the pumps utilized in a chemical synthesis plant are electrified.

[0084] As described above, in embodiments, a majority, greater than 20%, greater than 30%, greater than 40%, greater than 50%, greater than 60%, greater than 70%, greater than 80%, or greater than 90%, or substantially all, of the net energy required for the separation is supplied from non-carbon-based energy sources, from renewable energy sources such as renewable electricity, or from electricity (from any source, renewable and / or non-renewable). According to embodiments of the present disclosure, various separations can be performed electrically. Separations based on temperature and / or pressure changes can include electrical heating / cooling and / or compression, as described above. For example, in embodiments of the present disclosure, distillation, gas / solid separation, absorption, stripping, solvent extraction, extractive distillation, pressure swing adsorption, temperature swing adsorption, flash separation, crystallization, or combinations thereof, can be electrified. As a non-limiting example, in embodiments, distillation columns in one or more sections of a plant can be electrically heated. In embodiments, reboilers associated with distillation columns are electrically heated and / or heated via electrically generated steam (or another fluid). In embodiments, the reboiler associated with the distillation column is heated by an electric immersion heater. In embodiments, electricity is used to power a thermoelectric device or heat pump to provide both heating (to the reboiler) and cooling (to the condenser) within the distillation column. In embodiments, water vapor for use in stripping is generated electrically.

[0085] As discussed above, when utilizing electricity from renewable sources with potential or known intermittent supplies (e.g., intermittent energy sources, or IES), various steps can be taken to maintain operation of the chemical synthesis plant, according to aspects of the present disclosure.

[0086] Referring to FIG. 4, which is a schematic diagram of a chemical synthesis plant II according to an embodiment of the present disclosure, the net energy required throughout the chemical synthesis plant II of the present disclosure, E NET (e.g., for power supply 101, pumping 102, heating 103, cooling 104, compression 105, and / or separation 106, etc.) may utilize intermittent energy E when an intermittent energy source (e.g., the sun) is available. I(e.g., electricity from renewable energy sources) and, when intermittent energy sources are not available, stored intermittent energy (E SI ) and / or non-intermittent energy source E NI (e.g., electricity from an uninterrupted source, which may be live or stored).

[0087] As shown in the embodiment of Figure 4, I Various energy storage devices 50 may be utilized to store energy, e.g., available intermittent energy E I By utilizing the chemical synthesis plants and methods of the present disclosure, it is possible to provide a substantially continuous operation of chemical synthesis while utilizing primarily energy from IES, which may be renewable IES.

[0088] 5A-5D, various energy storage systems and methods will now be described for use in a chemical synthesis plant II operated by an IES according to the present disclosure.

[0089] In embodiments, compression can be used to store energy due to intermittent electrical supplies. FIG. 5A is a schematic diagram of a system IIIA for storing energy by compression according to embodiments of the present disclosure. In embodiments, a storage stream 40A comprising a gaseous feed is compressed in a compressor C1, and the resulting compressed stream 41A is stored in a storage vessel 50A due to intermittent energy (e.g., electrical energy) supplies. The storage stream 40A can include one or more feed streams, one or more chemical products, or one or more intermediates produced by a chemical synthesis process. After storage, at least a portion 42A of the stored compressed material can be returned to the chemical synthesis process as a process stream (e.g., if intermittent electricity is not available to operate the compressor utilized to provide the compressed material). In embodiments, the gaseous feed is compressed in a compressor C1 at a pressure higher than the process operating pressure and stored in a storage vessel 50A. For example, the gaseous feed may, in embodiments, be compressed to a "high" pressure of about 1 MPa or greater, about 10 MPa or greater, or about 100 MPa or greater, and / or stored at a "high" pressure of about 1 MPa or greater, about 10 MPa or greater, or about 100 MPa or greater. In embodiments, when the pressure of the stored compressed stream is reduced, electricity may be generated and / or mechanical work may be performed.

[0090] In embodiments, the gaseous feed is compressed and liquefied when intermittent electricity is readily available and / or economical, and vaporized and expanded to generate electricity and / or provide feed elsewhere within chemical synthesis plant I when intermittent electricity is not readily available and / or economical. For example, as shown in the embodiment of FIG. 5A , energy storage system IIIA can include an expander 45 operable to expand at least a portion 43A of the compressed stored stream to provide work W. Expander 45, in embodiments, can be a turboexpander. In embodiments, the work can be utilized to generate energy for use elsewhere throughout the system. For example, expander 45 can be used to drive a compressor or generator 46, thereby providing compression or electricity, respectively. Following expansion in expander 45, reduced pressure stream 43A' may be returned to the chemical synthesis process (e.g., via stream 42') as a feed stream therein, and / or sent for storage or sale, or may be recompressed in compressor C1 and stored in storage vessel 50A when the IES becomes available again.

[0091] In embodiments, a storage stream comprising oxygen or nitrogen produced in an air separation plant (e.g., an electrically powered ASU that may be operable to provide oxygen or nitrogen to chemical synthesis) may be stored under pressure (e.g., in storage vessel 50A) for later use, and electricity may be generated by expansion in expander 45. In embodiments, storage stream 40A comprises hydrogen. In embodiments, storage stream 40A comprises methane. In embodiments, storage stream 40A comprises ethane. In embodiments, storage stream 40A comprises propane.

[0092] Alternatively or additionally, one or more chilled fluids or cryogenic liquids may be stored due to intermittent electrical supply. FIG. 5B is a schematic diagram of a system IIIB for storing energy by cooling according to an embodiment of the present disclosure. In an embodiment, a storage stream 40B containing a fluid utilized or produced within a chemical synthesis plant (e.g., one or more feed streams, one or more chemical products, one or more intermediates, or a previously used refrigerant produced by a chemical synthesis process) is cooled in a cooling or refrigeration device 60, and the resulting cooled stream 41B is stored in a storage vessel 50B due to intermittent energy (e.g., electrical energy) supply. In an embodiment, a feed, intermediate, or product / by-product is cooled and stored for use as a refrigerant due to intermittent electrical supply. In an embodiment, nitrogen is cooled and stored for use as a refrigerant due to intermittent electrical supply. At least a portion of the stored cooled material 42B can be returned to the chemical synthesis process as a process stream after storage (e.g., when intermittent electricity is not available to operate the chiller utilized to provide the chilled material). In embodiments, at least a portion of the cooled stored stream 43B and a process stream 71 of the chemical synthesis plant can be introduced into heat exchanger 70, whereby heat exchange between process stream 71 and at least a portion of the stored cooled material 43B produces a cooled process stream 71A and a heated stream 43B' comprising a now relatively warm material (e.g., gas or liquid). Through this storage system and method, materials produced in the chemical synthesis process (e.g., propane or ammonia) can, in embodiments, be cooled (e.g., by introducing it into chiller 60 via storage stream 40B) when intermittent electricity is readily available and used in heat exchanger 70 to cool streams throughout the chemical synthesis plant (e.g., process stream 71) when electricity is not available. The resulting relatively warm liquid or gas (e.g., in heated stream 43B') can then be utilized as feed and / or removed as product. In embodiments, as the stored cooled material warms, the pressure increases and the gas expands through an expander to provide work.In embodiments, the expander may be a turboexpander. In embodiments, work can be utilized to generate energy for use elsewhere throughout the system. For example, the expander may be used to drive a compressor or a generator, thereby providing compression or electricity, respectively. After expansion, the reduced-pressure stream may be returned to the chemical synthesis process, for example, as a feed stream therein, and / or sent for storage or sale, or may be recompressed and stored when the IES becomes available again. That is, in embodiments, both pressure energy and refrigeration are stored. Because warming the refrigerant provides pressure, this pressure can also be utilized to provide energy throughout the plant.

[0093] Alternatively or additionally, hydrogen (e.g., compressed hydrogen) may be stored and / or passed through a fuel cell due to intermittent electrical supply. In embodiments, a storage stream containing hydrogen may be stored and then passed through a fuel cell to generate electricity to address intermittent electrical supply. FIG. 5C is a schematic diagram of a system IIIC for storing energy with hydrogen according to embodiments of the present disclosure. In embodiments, a storage stream 40C containing hydrogen is stored in a storage vessel 50C due to intermittent energy (e.g., electrical energy) supply. In embodiments, system IIIC includes a compressor C1, where the storage hydrogen in storage stream 40C is compressed in compressor C1, and the compressed hydrogen in compressed hydrogen stream 41C is stored in storage vessel 50C. In embodiments, the hydrogen-containing storage stream 40C, the compressed storage stream 41C, and / or the stored hydrogen stream 43C (which may include compressed or uncompressed hydrogen in embodiments) may be introduced into a fuel cell 80 of system IIIC. Fuel cell 80 may comprise any fuel cell (or flow cell) operable to generate electricity from hydrogen. For example, fuel cell 80 may comprise a proton exchange membrane (PEM) fuel cell (PEMFC) (also known as a polymer electrolyte membrane fuel cell), a solid oxide fuel cell (SOFC), or the like. Fuel cell 80 is operable to generate electricity, shown at 84 (and water, shown at 83), by the introduction of hydrogen and air thereto via storage stream 40C and / or stored hydrogen stream 43C and 81, respectively. Emissions may be removed at 82. Generated heat, shown at 85, may be “waste” heat or, in embodiments, may be utilized elsewhere in the chemical synthesis plant (e.g., for cogeneration or process heating).

[0094] Alternatively or additionally, hydrogen (e.g., compressed hydrogen) is stored and / or combusted due to the intermittency of the electrical supply. In embodiments, a storage stream containing hydrogen is stored and then combusted to produce steam and heat. In embodiments, high-temperature steam is used as a reactant or process diluent. In embodiments, the temperature of the high-temperature steam is higher than the temperature of the process stream to which it is added, resulting in an increase in the temperature of the process stream. In embodiments, combustion is used to generate electricity (e.g., in a turbine).

[0095] Alternatively or additionally, heat may be stored due to intermittent electrical supply. In embodiments, heat (e.g., as a heated or superheated fluid) is stored to heat one or more process streams when electrical heating is unavailable. FIG. 5D is a schematic diagram of a system IIID for storing energy by heating according to an embodiment of the present disclosure. In an embodiment, storage stream 40D, including a process stream (e.g., one or more feed streams, one or more chemical products, or one or more intermediates produced by a chemical synthesis process), is heated in heating device 90 (which in embodiments may be an electrically heated device) and stored in storage vessel 50D due to intermittent energy (e.g., electrical energy) supply. Heating device 90 is configured to heat the storage stream introduced thereto via storage stream 40D. Heating device 90 may be any heating device known to those skilled in the art. In an embodiment, heating device 90 comprises an electrically heated heating device. Heated stream 41D is introduced into storage vessel 50D for storage. The stored heated stream may be introduced into heat exchanger device 91 to transfer heat from stored heated stream 43D to process stream 71 of the chemical synthesis process. Heated process stream 71A and cooled heat exchanger fluid 43D, which includes the stored heated stream after heat exchange therewith, may be removed from heat exchanger device 91. The heat exchanger may be any heat exchanger device known to those skilled in the art. In embodiments, heated process stream 71B, the cooled heat exchange stream in cooled heat exchanger fluid 43D, or both, may be returned to the chemical synthesis process.

[0096] Alternatively or additionally, in embodiments, thermal energy can be stored by heating a solid or liquid heat storage material. This material can be heated by the process stream or directly by a dedicated heating device. In embodiments, the dedicated heating device is electrically powered. Heat can then be recovered by heat exchange with the process stream to be heated. In embodiments, the solid or liquid heat storage material is a molten salt.

[0097] Alternatively or additionally, thermal energy can be stored using one or more phase change materials (e.g., from a process stream or IES) in which thermal energy is captured as latent heat of liquefaction by melting the material. The energy can be recovered by directly or indirectly thermally contacting the process stream with the phase change material and solidifying the material. By appropriate selection of the phase change material, thermal energy can be stored at any desired temperature. In embodiments, the phase change material can provide process heating at the same temperature as the phase change. For example, sodium nitrite, which has a melting point of approximately 271°C, can be used as a phase change material to store and release thermal energy at or near this relatively high temperature. Alternatively, boron oxide, which has a melting point of approximately 450°C, can be used as a phase change material to store and release thermal energy at or near this relatively high temperature, suitable, for example, for preheating a gas stream containing N2 and H2 to a temperature suitable for ammonia synthesis. In embodiments, the phase change material can be melted using an electric heater, wherever an IES is available, or by extracting some of the heat present in the process stream.

[0098] Alternatively or additionally, in embodiments, energy can be stored as gravitational potential energy. When renewable energy is available, a mass (e.g., liquid or solid) can be increased. The increased mass can then be reduced so that energy can be recovered to generate electricity and / or perform mechanical work. In embodiments, the mass is a product or feed. In embodiments, the mass is water.

[0099] Alternatively or additionally, the energy storage device 50 of FIG. 4 comprises a battery that is maintained for intermittent electrical supply.

[0100] It should be understood that intermittency can occur on a variety of time scales, ranging from subsecond (e.g., very short interruptions in electricity supply) to months (e.g., due to seasonal variations in wind power generation). In aspects, the systems and methods herein relate to diurnal intermittency, i.e., daily variations in IES availability due, for example, to variations in solar or wind power generation. The systems and methods described above can be applied to intermittency on any time scale. For intermittency on relatively short time scales (e.g., seconds, minutes, or hours), additional methods and systems may be utilized, as described below.

[0101] In embodiments, the reactor(s) are lined or insulated with refractory material such that a brief loss of power does not significantly reduce the temperature of the refractory-lined or adiabatic reactor(s). In embodiments, the temperature loss is less than 10° C. for at least 2 minutes, or less than 5° C. for at least 2 minutes, or less than 10° C. for at least 5 minutes, or less than 10° C. for at least 10 minutes, or less than 20° C. for at least 30 minutes.

[0102] In embodiments, one or more reactors are constructed in thermal communication with a body of large thermal mass such that the body heats during normal operation, but can provide heat to the reactors during brief power losses such that the temperature of the reactors does not drop significantly. In embodiments, the temperature loss is less than 5° C. for at least 2 minutes, or less than 2° C. for at least 2 minutes, or less than 5° C. for at least 5 minutes, or less than 10° C. for at least 15 minutes, or less than 20° C. for at least 45 minutes.

[0103] In embodiments, one or more reactors are thermally coupled to a phase change material selected to have a melting point close to the desired temperature of the reactor. If an IES is available, the phase change material remains in a liquid state. If an IES is not available, the cooling and solidification of the phase change material can provide heat to the reactor, resulting in no significant temperature loss to the reactor. In embodiments, the temperature loss is less than 4°C for at least 2 minutes, or less than 5°C for at least 5 minutes, or less than 5°C for at least 10 minutes, or less than 10°C for at least 30 minutes, or less than 20°C for at least 90 minutes.

[0104] Alternatively or additionally, energy storage device 50 includes backup power for key components (e.g., reactors necessary to maintain production of one or more chemical products, or components such as compressors to maintain a safe flow of gas). For example, in embodiments, the energy storage device comprises a flywheel. In embodiments, the energy storage device comprises one or more capacitors. In embodiments, the energy storage device comprises a chemical battery for storing electricity. In embodiments, the energy storage device comprises a system utilizing superconductors or supercapacitors. In embodiments, the energy storage device comprises a thermal battery. In embodiments, the energy storage device comprises compressed air or other gas. In embodiments, the energy storage device comprises a suitable stored fuel and a fuel cell. In embodiments, the energy storage device comprises a suitable stored fuel and a combustor, such as a furnace. In embodiments, the stored fuel is obtained from a renewable or non-fossil fuel source.

[0105] Alternatively or additionally, if a chemical synthesis plant cannot provide enough stored energy to operate the entire plant while addressing the IES, it can store enough energy to address some energy demands and put other parts of the plant on standby until additional energy is available from the IES. In embodiments, if an IES is unavailable, intermediate products are stored before entering all or part of product purification section 30 of FIG. 3 . Product purification resumes when an IES is again available. In embodiments, for example, regeneration of dryers, adsorber, and / or catalyst beds is postponed if an IES is available. In embodiments, product pumping to off-site storage or sale occurs only if an IES is available. In embodiments, solids processing operations, such as extrusion or bagging, are placed on standby if an IES is unavailable. In embodiments, the chemical synthesis plant is operated at a relatively low throughput (i.e., less feed is processed and less product is produced) until more energy is available.

[0106] Alternatively or additionally, it may not be possible to provide sufficient stored energy to handle the absence of an IES over an extended period of time or due to unexpected loss of the IES. In embodiments, sufficient energy storage is provided (e.g., in energy storage device 50) to enable safe shutdown of the plant. Safe shutdown can encompass protecting the safety of plant workers, protecting the physical and mechanical integrity of all plant components, preventing the release of potentially hazardous or regulated substances, avoiding contamination or poisoning of catalysts, solutions, or equipment, enabling orderly restart if an IES is available, and / or preventing the waste of valuable feeds, products, or intermediates.

[0107] In embodiments, dual-energy systems or devices capable of using multiple energy sources may be utilized to address IES. For example, a chemical synthesis plant of the present disclosure may include a steam or gas turbine-driven compressor as a backup for an electric motor-driven compressor. In embodiments, for example, non-renewable electricity may be utilized as a backup for intermittent renewable electricity to power the electric motor-driven compressor when IES is unavailable or uneconomical.

[0108] In embodiments, some or all of the plant's control system is integrated with actual and / or predicted cost data of IES and other energy sources. In embodiments, plant operation, energy supply selection, and / or the amount of energy stored are optimized to improve operability, profitability, and safety. In embodiments, this integration and / or optimization can occur in real time.

[0109] Electrification of the chemical synthesis plant of the present disclosure can be provided via an electrical supply, which can be high voltage or low voltage. The electrical equipment can be operable or operated on alternating current (single phase or polyphase) or direct current.

[0110] Because energy consumption (e.g., to maintain desired temperatures and pressures) accounts for a large portion of the operating costs of conventional chemical synthesis plants, improved energy efficiency (e.g., through electrification) according to the present disclosure and / or utilizing one or more components traditionally burned to provide heat and / or for compression (e.g., burned in a reactor to maintain the desired operating temperature, burned to generate steam for a steam turbine, and / or burned for a gas turbine) to produce additional chemical products can provide economic advantages over conventional chemical synthesis plants. In embodiments, aspects of the present disclosure (e.g., elimination of expensive steam systems) can help reduce the large investment costs required to build new chemical facilities. At the same time, the reduction in burning fossil fuels (e.g., natural gas, methane) as fuel, enabled by the present disclosure, reduces greenhouse gas (GHG) emissions compared to conventional chemical synthesis plants in which hydrocarbons are burned as fuel. In embodiments, GHG emissions (e.g., carbon dioxide emissions) are reduced by at least 5, at least 10, at least 20, at least 25, at least 30, at least 40, at least 50, at least 60, at least 70, at least 80, at least 90, at least 95, at least 98, or at least 100% compared to conventional chemical synthesis plants in which hydrocarbons are burned as fuel. In embodiments, aspects of the present disclosure can result in an increase in the carbon efficiency of the process, i.e., the fraction of carbon consumed in the process that reappears as useful products, and / or a reduction in specific energy consumption (e.g., the energy utilized to synthesize a certain amount of chemical product). In embodiments, the specific energy consumption (net external energy supplied to the process divided by the amount of product produced; also referred to as net specific energy consumption) is reduced by at least about 5%, at least about 10%, at least about 20%, at least about 30%, at least about 40%, at least about 50%, at least about 60%, at least about 70%, at least about 80%, at least about 90%, at least about 95%, at least about 98%, or at least about 100% over an otherwise similar conventional process.

[0111] Traditionally, the energy required for unit operations in chemical processes is generally provided by burning fossil fuels, particularly natural gas. Disclosed herein are systems and methods in which this energy input can be reduced or replaced by non-carbon-based energy, renewable energy, such as renewable electricity, and / or electricity from any source (e.g., renewable and / or non-renewable), thereby improving energy efficiency (e.g., reducing energy losses). The use of non-carbon-based energy, renewable energy, and / or electricity disclosed herein in the production of chemicals can improve the energy efficiency of chemical synthesis processes, reduce carbon dioxide emissions from chemical synthesis processes, reduce fossil energy consumption within chemical synthesis processes, and provide additional supplies by reducing or eliminating the burning of feed components as fuel.

[0112] Through the systems and methods disclosed herein for providing chemical synthesis via an IES, chemical synthesis can be maintained substantially continuously while utilizing the IES for at least a portion, some, or substantially all of the net energy required for the chemical synthesis. In accordance with the present disclosure, various energy storage systems provided herein can be incorporated to produce chemicals via an IES, thereby allowing the IES to provide some or substantially all of the net energy required for synthesis even during times when the IES is not available. [Example]

[0113] Having generally described embodiments, the following examples are given to demonstrate the practice and advantages of certain embodiments of the disclosure, it being understood that the examples are given by way of illustration and are not intended to limit the scope of the specification or claims in any way.

[0114] Example 1: Electrified Olefin Synthesis (e.g., Cracking) + PSA 6 shows the operating parameters of olefin synthesis process VII, which is electrified according to one embodiment of the present disclosure and is shown in Examples 1 and 2. Process VII includes a gas separation unit 260, which may include a pressure swing adsorption (PSA) unit. Gas separation unit 260 is configured to purify hydrogen- and methane-containing stream 244. Stream 244 has a flow rate of 30.1 t / hr and contains 48 wt% (88 mol%) hydrogen and 52 wt% (12 mol%) methane. Gas separation unit 260 (e.g., PSA gas separation unit 260) consumes 3 MW of electricity and produces two product streams: methane stream 247, which consists essentially of pure methane, and hydrogen stream 248, which consists essentially of pure hydrogen. Via this Process VII, the purified hydrogen produced in PSA 260 in the amount of 14.3 t / hr can be fed to fuel cell 270, where the hydrogen is converted to water in water stream 249 and to electricity E at an electrical efficiency of 45%, resulting in the continuous production of 253 MW of electricity. The net electricity (250 MW) is used to provide 41% of the 603 MW of electricity required for Process VII.

[0115] Example 2: Electrified Olefin Synthesis (e.g., Cracking) + PSA and H Compression / Storage In an embodiment, Process VII described in Example 1 further comprises a hydrogen compression and storage device 280, which comprises at least one compressor and a storage vessel and is configured to compress and store the resulting 14.3 t / hr of purified hydrogen (which may be introduced thereto via line 248A) for use when renewable electricity availability is relatively low or relatively expensive. If desired, the compressed and stored hydrogen may be combined (e.g., via line 248B) with hydrogen currently being produced by Process VII (e.g., hydrogen in line 248), and both may be converted to electricity using fuel cell 270. The timing of using the stored hydrogen for electricity generation may be determined by one skilled in the art according to various factors. As one possibility, if some renewable electricity is available on a daytime basis, 172 tons of hydrogen can be collected and stored for 12 hours. When released over the next 12 hours and combined with the 14.3 t / hr of hydrogen still being produced by the process, approximately 503 MW of electricity would be available for 12 consecutive hours. This will provide 80% of the 603MW of electricity needed to operate the process.

[0116] Example 3: Electrified Ammonia Synthesis - Electrified Primary Reforming (SMR) + PSA FIG. 7 shows the operating parameters of ammonia synthesis Process XII, electrified according to one embodiment of the present disclosure and shown in Examples 3 and 4. Process XII includes an electric compressor, an electric reformer, and an electric reboiler. As shown by the dashed line in FIG. 7, a pressure swing adsorption (PSA) gas separation unit 267 is further added to purify purge gas stream 205′. At a flow rate of 16.7 t / hr, this purge gas stream 205′ contains 11 wt.% hydrogen. Gas separation unit 267 consumes 2 MW of electricity and produces essentially pure hydrogen product stream 268. The resulting 1.84 t / hr of purified hydrogen is fed to fuel cell 270, where the hydrogen is converted to water 271 and electricity 272 at an electrical efficiency of 45%, resulting in the continuous production of 33 MW of electricity. Net electricity (31 MW) is used to provide 8.3% of the 375 MW of electricity required for Process XII.

[0117] Example 4: Electrified Ammonia Synthesis - Electrified Primary (SMR) Reforming + PSA and H2 Compression / Storage Process XII, described in Example 3, further includes a pressure swing adsorption (PSA) gas separation unit 267 to purify purge gas stream 205′. At a flow rate of 16.7 t / hr, this purge gas stream 205′ contains 11% hydrogen by weight. Gas separation unit 267 consumes 2 MW of electricity and produces an essentially pure hydrogen product stream 268. The resulting 1.84 t / hr of purified hydrogen is compressed by compressor C4 and stored in storage vessel 280 for use when renewable electricity availability is relatively low or expensive. If needed, the hydrogen stored in storage vessel 280 is combined with hydrogen currently being produced by the process at 268, and both are converted to electricity 272 using fuel cell 270. The timing of using the stored hydrogen for electricity generation depends on various factors. In one possibility, if some renewable electricity is available on a daytime basis, 22.1 tons of hydrogen can be collected and stored for 12 hours. When released over the next 12 hours and combined in line 268 with the 1.84 t / hr of hydrogen still being produced by the process, approximately 64 MW of electricity 272 will be available for 12 continuous hours, providing 17% of the 375 MW of electricity required to operate Process XII.

[0118] Example 5: Electrified Methanol Synthesis + PSA 8 shows the operating parameters of methanol synthesis process X / XI, electrified according to one embodiment of the present disclosure and shown in Examples 5 and 6. Process X comprises a pressure swing adsorption (PSA) gas separation unit 295 and a fuel cell 296. PSA 295 is operable to purify purge gas stream 205' and recover 80% of the available 3.37 t / h of hydrogen. The resulting 2.7 t / h of purified hydrogen 293 is fed to fuel cell 296, where the hydrogen is converted to water 291 and electricity 296 at an electrical efficiency of 45%, resulting in the continuous production of 48 MW of electricity. This electricity is used to provide approximately 27% of the 180 MW of electricity required for process X.

[0119] Example 6: Electrified Methanol Synthesis + PSA and H2 Compression / Storage As shown by the dashed lines in FIG. 8 , Process XI according to the present disclosure includes a compressor C4 and a storage vessel 297. A pressure swing adsorption (PSA) gas separation unit 295 purifies purge gas stream 205′ and is operable to recover 80% of the available 3.37 t / h of hydrogen. The resulting 2.7 t / h of purified hydrogen 293 is compressed with C4 and stored in storage vessel 297 for use when renewable electricity availability is relatively low or relatively expensive. If needed, the stored hydrogen 293A is combined with hydrogen 293 currently being produced by Process XI, and both are converted to electricity using a fuel cell 296. The use of stored hydrogen for electricity generation is determined by various factors, as will be understood by those skilled in the art. As one possibility, if some renewable electricity is available on a daytime basis, 32.4 tons of hydrogen can be collected, compressed with C4, and stored in 297 for 12 hours. Released over the next 12 hours and combined with the 2.7 t / h of hydrogen 293 still being produced by Process IX via stored hydrogen stream 293A, approximately 96 MW of electricity may be available for 12 continuous hours. This electricity provides approximately 53% of the 180 MW of electricity required to operate Process XI.

[0120] While various embodiments have been shown and described, modifications thereof may be made by those skilled in the art without departing from the spirit and teachings of the present disclosure. The embodiments described herein are illustrative only and are not intended to be limiting. Many variations and modifications of the subject matter disclosed herein are possible and are within the scope of the present disclosure. When numerical ranges or limits are explicitly stated, such explicit ranges or limits should be understood to include iterative ranges or limits of similar magnitude that fall within the explicitly stated range or limit (e.g., about 1 to about 10 includes 2, 3, 4, etc.; greater than 0.10 includes 0.11, 0.12, 0.13, etc.). For example, a lower limit R L and upper bound R U Whenever a numerical range having a value of R = R is disclosed, any number falling within that range is specifically disclosed. In particular, the following numbers falling within the range are specifically disclosed: R = R L +k*(R U -R L ), where k is a variable ranging from 1% to 100% in 1% increments, i.e., k is 1 percent, 2 percent, 3 percent, 4 percent, 5 percent, ... 50 percent, 51 percent, 52 percent, ... 95 percent, 96 percent, 97 percent, 98 percent, 99 percent, or 100 percent. Additionally, any numerical range defined by two R numbers defined above is specifically disclosed. The use of the term "optionally" with respect to any element of a claim is intended to mean that the subject element is required, or is not required. Both alternatives are intended to be within the scope of the claim. The use of broad terms such as "comprises," "includes," and "having" should be understood to provide support for narrower terms such as "consisting of," "consisting essentially of," and "comprised substantially of."

[0121] Accordingly, the scope of protection is not limited by the above description, but only by the appended claims, which scope includes all equivalents of the subject matter of the claims. Each and every claim is incorporated herein as an aspect of this disclosure. Accordingly, the claims are further explanation and in addition to the aspects of this disclosure. No admission is made that the discussion of any reference, especially any reference that may have a publication date after the priority date of this application, is prior art to the present disclosure. The disclosures of all patents, patent applications, and publications cited herein, to the extent that they provide exemplary, procedural, or other details supplementary to those set forth herein, are incorporated herein by reference.

[0122] Additional Disclosures Section I The specific embodiments disclosed above are illustrative only, as the disclosure may be modified and practiced in different but equivalent manners apparent to those skilled in the art having the benefit of the teachings herein. Furthermore, no limitations are intended to the details of construction or design shown herein, other than as described in the appended claims. It is therefore apparent that the specific exemplary embodiments disclosed above may be altered or modified, and all such variations are considered to be within the scope and spirit of the present disclosure. Alternative embodiments resulting from combining, integrating, and / or omitting features of the embodiments are also within the scope of the present disclosure. While compositions and methods are described in broad terms such as "having," "comprising," "containing," or "including" various components or steps, compositions and methods can also "consist essentially of" or "consist of" various components and steps. The use of the term "optionally" with respect to any element of a claim means that either the element is required or the element is not required, with both options being within the scope of the claim.

[0123] The numbers and ranges disclosed above may vary to some extent. Whenever a numerical range with a lower and upper limit is disclosed, every number falling within that range and every encompassed range is specifically disclosed. In particular, any range of values ​​disclosed herein (in the form "from about a to about b" or, equivalently, "from approximately a to b" or, equivalently, "from approximately a to b") should be understood to represent every number and range encompassed within the broader range of values. Furthermore, terms in the claims have their plain and ordinary meaning unless expressly and unambiguously defined otherwise by the patent owner. Furthermore, the indefinite article "a" or "an," when used in a claim, is defined herein to mean one or more of the elements it introduces. In the event of any discrepancy in the use of a word or term in this specification and one or more patents or other documents, the consistent definition in this specification should prevail.

[0124] Aspects disclosed herein include the following.

[0125] A: A chemical synthesis plant comprising: one or more reactors configured to produce a process stream comprising at least one chemical product from one or more reactants; a feed preparation system configured to prepare one or more feed streams comprising one or more of the one or more reactants for introduction into the reactor(s); and / or a product purification system configured to separate the at least one chemical product from reaction by-products, unreacted reactants, or combinations thereof in the process stream, wherein the chemical synthesis plant is configured such that a majority (e.g., greater than 50%, greater than 60%, greater than 70%, greater than 80%, greater than 90%, or greater than 100%) of the net energy required for heating, cooling, compression, or combinations thereof utilized via the one or more reactors, feed preparation system, product purification system, or combinations thereof is supplied from an intermittent energy source (IES).

[0126] B: A chemical synthesis plant configured for operation that utilizes electricity from renewable intermittent energy sources (IES) to provide a majority (e.g., more than 50%, more than 60%, more than 70%, more than 80%, more than 90%, or more than 100%) of the net energy required for heating, cooling, compression, or a combination thereof.

[0127] Each of Embodiments A and B may have one or more of the following additional elements: Element 1: The chemical synthesis plant further comprises one or more compressors configured to compress at least one stream comprising one or more of the reactants, at least one of the chemical products, or at least one intermediate produced by the process, and a storage device configured to store at least one compressed stream for later use. Element 2: The chemical synthesis plant further comprises an apparatus for expanding at least one stored compressed stream to generate electricity and / or perform mechanical work. Element 3: The chemical synthesis plant further comprises a cooling device configured to cool at least one stream selected from one or more of the reactants, at least one of the chemical products, or at least one intermediate produced by the process, and a storage device configured to store at least one cooled stream for later use. Element 4: The at least one cooled stream comprises a cryogenic liquid. Element 5: The one or more reactors, feed preparation system, product purification system, or combinations thereof are configured for the production of hydrogen, and the chemical synthesis plant further comprises a fuel cell for converting at least a portion of the produced hydrogen to electricity. Element 6: Further comprising a hydrogen storage device for storing at least a portion of the hydrogen produced prior to converting at least a portion of the hydrogen produced using the fuel cell to electricity when an intermittent power source is not available. Element 7: Further comprising a compressor upstream of the hydrogen storage device configured to compress the hydrogen before storing it. Element 8: The one or more reactors, feed preparation system, product purification system, or combination thereof are configured for production of hydrogen, and the chemical synthesis plant further comprises a hydrogen storage device and a compressor upstream of the hydrogen storage device, the compressor configured to compress at least a portion of the produced hydrogen before storing it, and the chemical synthesis plant further comprises a combustion device for combusting a portion of the stored hydrogen to produce steam and / or heat when an intermittent power source is not available, and optionally the steam may be used as a reactant or diluent.Element 9: Further comprising a device for storing energy by increasing agglomeration when an intermittent power source is available. Element 10: The agglomeration includes one or more feeds, one or more products, or water. Element 11: The one or more reactors are lined with a refractory material such that a short-term power loss does not cause a temperature drop of more than about 10°C in two minutes in the one or more refractory-lined reactors. Element 12: The one or more reactors are thermally connected to a thermal mass such that a short-term power loss does not cause a significant temperature drop of more than about 5°C in two minutes in the one or more refractory-lined reactors. Element 13: The one or more reactors are thermally connected to a phase change material such that a short-term power loss does not cause a temperature drop of more than about 4°C in two minutes in the one or more refractory-lined reactors. Element 14: Further comprising a device operable to store heat (e.g., a heated or superheated fluid) for heating one or more process streams when an IES is not available. Element 15: Further comprising a device configured to utilize liquefaction of a phase change material to store energy. Element 16: Further comprising an on-site battery to address intermittent electrical supply. Element 17: Further comprising a backup power device configured to provide backup power to at least one device of the chemical synthesis plant. Element 18: The backup power device is selected to provide sufficient energy to ensure safe shutdown of the plant. Element 19: The backup power device comprises a device powered by compressed gas, a capacitor, a superconductor, a thermal battery, and / or a flywheel. Element 20: At least a portion of the plant operates only if an IES is available. Element 21: Configured to operate at a reduced production rate when an IES is unavailable or a reduced amount of IES is available. Element 22: Further comprising a system for receiving information regarding energy prices and availability, whereby this information can be used to optimize energy usage, energy storage, and plant operation.Element 23: The system further comprises one or more compressors operable to compress one or more gaseous feed streams for storage when an IES is available and / or below a threshold price, such that at least a portion of the compressed one or more feed streams can be utilized as a feed stream and / or to provide electricity and / or mechanical work when an IES is not available and / or above a threshold price. Element 24: The one or more compressors compress and liquefy one or more gaseous feed streams when electricity from an IES is available and / or below a threshold price, and the system further comprises a device operable to vaporize and expand the liquefied gaseous feed stream(s) to generate electricity, perform mechanical work, and / or provide a supply when an IES is not readily available and / or above a threshold price. Element 25: The system further comprises one or more chillers configured to cool one or more feed streams, product streams, and / or another fluid, and a storage device configured to store the cooled one or more feed streams, product streams, and / or another fluid for use as a refrigerant when an IES is not available and / or above a threshold price. Element 26: The refrigerant includes methane, ethane, propane, butane, pentane, ethylene, propylene, ammonia, nitrogen, or a combination thereof. Element 27: Further comprising a fuel cell and a device for storing hydrogen, whereby hydrogen can be stored in the storage device and the stored hydrogen can be introduced into the fuel cell to generate electricity and address intermittent electricity supply from the IES. Element 28: Further comprising an air separation unit (ASU) configured to produce oxygen and nitrogen, a storage device configured to store at least a portion of the generated oxygen and / or nitrogen under pressure, and an expander, whereby the pressurized and stored oxygen and / or nitrogen can be utilized as reactants and / or utilized to generate electricity by expansion in the expander when the IES is unavailable and / or exceeds a threshold price. Element 29: Further comprising one or more dual devices operable to address availability of the IES.Element 30: The one or more dual units comprise one or more compressors driven by steam or gas turbines utilized as backups for one or more electric motor-driven compressors. Element 31: The plant consumes an average daily amount of at least 25 MW for heating, cooling, compression, or a combination thereof. Element 32: The amount of CO2 emitted is at least 10% less than a similar plant configured to operate without utilizing electricity from an IES. Element 33: The specific energy consumption is at least 10% less than a similar plant configured to operate without utilizing electricity from an IES.

[0128] Additional Disclosures Section II The following are non-limiting specific aspects according to the present disclosure.

[0129] A first embodiment is a chemical synthesis plant comprising one or more reactors configured to produce a process stream from one or more reactants, the process stream comprising at least one chemical product; a feed preparation system configured to prepare one or more feed streams comprising one or more of the one or more reactants for introduction to the reactors; and / or a product purification system configured to separate the at least one chemical product from reaction by-products, unreacted reactants, or combinations thereof in the process stream, wherein the chemical synthesis plant is configured such that a majority (e.g., greater than 50%, greater than 60%, greater than 70%, greater than 80%, greater than 90%, or greater than 100%) of the net energy required for heating, cooling, compression, or combinations thereof utilized via the one or more reactors, feed preparation system, product purification system, or combinations thereof is supplied from an intermittent energy source (IES).

[0130] A second embodiment, which is the chemical synthesis plant of the first embodiment, further comprising one or more compressors configured to compress at least one stream comprising one or more of said reactants, at least one of said chemical products, or at least one intermediate produced by said process, and a storage device configured to store at least one compressed stream for later use.

[0131] A third embodiment, which is the chemical synthesis plant of the second embodiment, further comprising an apparatus for expanding at least one stored compressed stream to produce electricity and / or perform mechanical work.

[0132] A fourth embodiment, which is the chemical synthesis plant of the first embodiment, further comprising a cooling device configured to cool at least one stream selected from one or more of said reactants, at least one of said chemical products, or at least one intermediate produced by said method, and a storage device configured to store at least one cooled stream for later use.

[0133] A fifth embodiment, which is the chemical synthesis plant of the fourth embodiment, wherein at least one cooled stream comprises a cryogenic liquid.

[0134] A sixth embodiment, which is the chemical synthesis plant of the first embodiment, wherein the one or more reactors, feed preparation system, product purification system, or combination thereof are configured for the production of hydrogen, and the chemical synthesis plant further comprises a fuel cell for converting at least a portion of the produced hydrogen into electricity.

[0135] A seventh embodiment, which is the chemical synthesis plant of the sixth embodiment, further comprising a hydrogen storage device for storing at least a portion of the hydrogen produced prior to converting at least a portion of the produced hydrogen using the fuel cell to electricity when an intermittent power source is not available.

[0136] An eighth embodiment, which is the chemical synthesis plant of the seventh embodiment, further comprising a compressor upstream of the hydrogen storage device, the compressor configured to compress hydrogen prior to storing the hydrogen.

[0137] A ninth embodiment, which is the chemical synthesis plant of the first embodiment, wherein the one or more reactors, feed preparation system, product purification system, or combination thereof are configured for production of hydrogen; wherein the chemical synthesis plant further comprises a hydrogen storage device and a compressor upstream of the hydrogen storage device, wherein the compressor is configured to compress at least a portion of the produced hydrogen prior to storage; and wherein the chemical synthesis plant further comprises a combustion device for combusting a portion of the stored hydrogen to produce steam and / or heat when intermittent power is not available; and optionally, wherein steam may be used as a reactant or diluent.

[0138] A tenth embodiment, which is the chemical synthesis plant of the first embodiment, further comprising an apparatus for storing energy by increasing agglomeration when an intermittent power source is available.

[0139] An eleventh embodiment, which is the chemical synthesis plant of the tenth embodiment, wherein the agglomeration comprises one or more feeds, one or more products, or water.

[0140] A twelfth embodiment, which is the chemical synthesis plant of the first embodiment, wherein the one or more reactors are lined with a refractory material such that a brief loss of power does not cause a temperature drop of more than about 10° C. in 2 minutes of the one or more refractory-lined reactors.

[0141] A thirteenth embodiment, which is the chemical synthesis plant of the first embodiment, wherein the one or more reactors are thermally connected to the thermal mass such that a brief loss of power does not cause a significant temperature drop of more than about 5° C. in two minutes in the one or more refractory-lined reactors.

[0142] A fourteenth embodiment, which is the chemical synthesis plant of the first embodiment, wherein the one or more reactors are thermally connected to the phase change material such that a brief loss of power does not cause a temperature drop of more than about 4° C. in two minutes in the one or more refractory-lined reactors.

[0143] A fifteenth embodiment, which is the chemical synthesis plant of the first embodiment, further comprising an apparatus operable to store heat (e.g., a heated or superheated fluid) for heating one or more process streams when an IES is not available.

[0144] A sixteenth aspect, which is the chemical synthesis plant of the first aspect, further comprising an apparatus configured to utilize liquefaction of a phase change material to store energy.

[0145] A seventeenth aspect, which is the chemical synthesis plant of the first aspect, further comprising an on-site battery to address intermittency of the electrical supply.

[0146] An eighteenth embodiment, which is the chemical synthesis plant of the first embodiment, further comprising a backup power device configured to provide backup power to at least one device of the chemical synthesis plant.

[0147] A nineteenth embodiment, which is the chemical synthesis plant of the eighteenth embodiment, wherein the backup power device is selected to provide sufficient energy to ensure safe shutdown of the plant.

[0148] A twentieth aspect, which is the chemical synthesis plant of the eighteenth aspect, wherein the backup power device comprises a device powered by compressed gas, a capacitor, a superconductor, a thermal battery, and / or a flywheel.

[0149] A twenty-first aspect, which is the chemical synthesis plant of the first aspect, wherein at least a portion of the plant operates only if an IES is available.

[0150] A twenty-second embodiment, which is the chemical synthesis plant of the first embodiment, configured to operate at a reduced production rate when no IES is available or a reduced amount of IES is available.

[0151] A twenty-third embodiment, which is the chemical synthesis plant of the first embodiment, further comprising a system for receiving information regarding energy prices and availability, whereby this information can be utilized to optimize energy usage, energy storage, and plant operation.

[0152] A twenty-fourth embodiment, which is a chemical synthesis plant configured for operation utilizing electricity from renewable intermittent energy sources (IES) to provide a majority (e.g., greater than 50%, greater than 60%, greater than 70%, greater than 80%, greater than 90%, or greater than 100%) of the net energy required for heating, cooling, compression, or a combination thereof.

[0153] A twenty-fifth embodiment, which is the chemical synthesis plant of the twenty-fourth embodiment, further comprising one or more compressors operable to compress one or more gaseous feed streams for storage when an IES is available and / or is below a threshold price, such that at least a portion of the compressed one or more feed streams may be utilized as feed streams and / or utilized to provide electrical and / or mechanical work when an IES is not available and / or above a threshold price.

[0154] A twenty-sixth embodiment, which is the chemical synthesis plant of the twenty-fifth embodiment, wherein the one or more compressors compress and liquefy the one or more gaseous feed streams when electricity from an IES is available and / or below a threshold price, and the system further comprises apparatus operable to vaporize and expand the liquefied gaseous feed stream(s) to generate electricity, perform mechanical work, and / or provide a supply when an IES is not readily available and / or above a threshold price.

[0155] A twenty-seventh embodiment, which is the chemical synthesis plant of the twenty-fourth embodiment, further comprising one or more chillers configured to cool one or more feed streams, product streams, and / or another fluid, and a storage device configured to store the cooled one or more feed streams, product streams, and / or another fluid for use as a refrigerant when an IES is not available and / or exceeds a threshold price.

[0156] A twenty-eighth embodiment, which is the chemical synthesis plant of the twenty-seventh embodiment, wherein the refrigerant comprises methane, ethane, propane, butane, pentane, ethylene, propylene, ammonia, nitrogen, or a combination thereof.

[0157] A twenty-ninth embodiment, which is the chemical synthesis plant of the twenty-fourth embodiment, further comprising a fuel cell and an apparatus for storing hydrogen, whereby hydrogen can be stored in the storage apparatus and the stored hydrogen can be introduced into the fuel cell to generate electricity to address intermittencies in the electricity supply from the IES.

[0158] A 30th embodiment, which is the chemical synthesis plant of the 24th embodiment, further comprising an air separation unit (ASU) configured to produce oxygen and nitrogen, a storage device configured to store at least a portion of the produced oxygen and / or nitrogen under pressure, and an expander, such that the pressurized and stored oxygen and / or nitrogen can be utilized as reactants and / or to generate electricity by expansion in the expander when IES is not available and / or exceeds a threshold price.

[0159] A thirty-first embodiment, which is the chemical synthesis plant of the twenty-fourth embodiment, further comprising one or more dual units operable to address the availability of IESs.

[0160] A thirty-second embodiment, which is the chemical synthesis plant of the thirty-first embodiment, wherein the one or more dual units include one or more compressors driven by steam or gas turbines utilized as backups for the one or more electric motor-driven compressors.

[0161] A thirty-third embodiment, which is the chemical synthesis plant of the twenty-fourth embodiment, wherein the plant consumes an average daily amount of at least 25 MW for heating, cooling, compression, or a combination thereof.

[0162] A thirty-fourth aspect, which is the chemical synthesis plant of the twenty-fourth aspect, wherein the amount of CO2 emitted is at least 10% less than a similar plant configured to operate without utilizing electricity from an IES.

[0163] A thirty-fifth aspect, which is the chemical synthesis plant of the twenty-fourth aspect, having a specific energy consumption that is at least 10% less than a similar plant configured to operate without utilizing electricity from an IES.

[0164] A thirty-sixth embodiment, a chemical synthesis plant operable with an intermittent energy supply (IES) as described herein.

[0165] Additional Disclosures Section III The following are non-limiting specific aspects according to the present disclosure.

[0166] Aspects disclosed herein include the following.

[0167] A: A method of producing one or more chemical products, comprising: preparing one or more feedstreams comprising one or more reactants for introduction into a reactor; reacting the one or more reactants in the reactor to produce a product stream comprising one or more chemical products; separating the one or more chemical products from reaction by-products, unreacted reactants, or a combination thereof in the product stream; and / or recycling one or more of the unreacted reactants and / or reaction by-products; and, if a renewable intermittent energy source (IES) is available, providing a majority (e.g., greater than 50%, greater than 60%, greater than 70%, greater than 80%, or greater than 90%) of the net energy required for powering, pumping, heating, cooling, compressing, separating, or a combination thereof utilized for one or more of the preparation, reaction, separation, recirculation, or a combination thereof with electricity generated from a renewable intermittent energy source (IES).

[0168] B: A method of operating, designing, and / or improving a chemical synthesis plant, including utilizing electricity from renewable intermittent energy sources (IES) to provide a majority (e.g., greater than 50%, greater than 60%, greater than 70%, greater than 80%, greater than 90%, or greater than 100%) of the net energy required for heating, cooling, compression, or a combination thereof, when the renewable IES is available and / or below a threshold price.

[0169] Each of embodiments A and B may have one or more of the following additional elements: Element 1: The method further comprises compressing at least one stream selected from one or more feed streams, one or more chemical products, or at least one intermediate produced by the method, and storing at least one compressed stream for later use. Element 2: The method further comprises expanding at least one stored compressed stream to generate electricity or to perform mechanical work. Element 3: The method further comprises cooling at least one stream selected from one or more feed streams, one or more chemical products, or at least one intermediate produced by the method, and storing at least one cooled stream for later use. Element 4: The at least one cooled stream comprises a cryogenic liquid. Element 5: The later use comprises use as a refrigerant. Element 6: The preparation, reaction, separation, or a combination thereof produces hydrogen, and the method further comprises converting at least a portion of the produced hydrogen to electricity using a fuel cell. Element 7: When an intermittent power source is not available, the method further comprises storing at least a portion of the hydrogen produced before converting at least a portion of the hydrogen produced using the fuel cell to electricity. Element 8: Further comprises compressing the hydrogen before storing it. Element 9: When an intermittent power source is not available, the method further comprises combusting at least a portion of the stored hydrogen to produce water vapor and heat, and optionally utilizing the water vapor as a reactant or diluent. Element 10: When an intermittent power source is available, the method further comprises storing energy by growing an agglomerate. Element 11: The agglomerate includes one or more feeds, one or more products, or water. Element 12: The one or more reactors are lined with a refractory material such that a brief loss of power does not cause a temperature drop of more than 10°C in two minutes of the one or more refractory-lined reactors. Element 13: Further comprises regulating the inlet pressure of at least one of the one or more feed streams with the simultaneous generation of electricity.Element 14: Further comprising thermally connecting one or more reactors to a thermal mass such that a short-term power loss does not cause a temperature drop of more than about 5°C in two minutes in the one or more refractory-lined reactors. Element 15: Further comprising thermally connecting one or more reactors to a phase change material such that a short-term power loss does not cause a temperature drop of more than about 4°C in two minutes in the one or more refractory-lined reactors. Element 16: Further comprising storing heat (e.g., a heated or superheated fluid) for heating one or more process streams when electrical heating from the IES is not available. Element 17: Further comprising utilizing liquefaction of a phase change material to store energy. Element 18: Further comprising storing an on-site battery for intermittent electrical supply from the IES. Element 19: Further comprising providing backup power to at least one device. Element 20: The backup power device is selected to provide sufficient energy to ensure safe shutdown of the plant. Element 21: Providing backup power via compressed gas, capacitors, superconductors, thermal batteries, and / or flywheel-driven devices. Element 22: Further comprising operating at least a portion of the plant only when IESs are available. Element 23: Further comprising operating at a reduced production rate when IESs are unavailable or a reduced amount of IESs is available. Element 24: Further receiving information regarding energy prices and availability and utilizing the information to optimize energy usage, energy storage, and / or production of one or more chemical products. Element 25: Further comprising compressing one or more gaseous process streams for storage when renewable IESs are available and / or below a threshold price, and utilizing at least a portion of the compressed one or more feed streams as feed streams and / or to provide electrical and / or mechanical work when renewable IESs are unavailable and / or above a threshold price.Element 26: The one or more gaseous process streams are compressed and stored at a pressure higher than the process operating pressure, further comprising generating electricity from a pressure drop from higher than the process operating pressure to the operating pressure. Element 27: The one or more gaseous process streams are compressed and liquefied when electricity from the renewable IES is available and / or below a threshold price, and vaporized and expanded to generate electricity, perform mechanical work, and / or provide power when electricity from the renewable IES is not readily available and / or above a threshold price. Element 28: The method further comprises cooling and storing the product stream and / or one or more process streams for use as a refrigerant for intermittent electricity supply from the renewable IES. Element 29: The product stream and / or one or more process streams comprise methane, ethane, propane, ethylene, propylene, ammonia, or a combination thereof. Element 30: The product stream and / or one or more process streams are cooled and stored when electricity from the renewable IES is readily available and / or below a threshold price, and are used to cool one or more other process streams when electricity from the renewable IES is not available and / or above a threshold price, thereby producing one or more relatively warm liquid and / or gas streams. Element 31: Further includes using one or more relatively warm liquid and / or gas streams obtained by cooling the product stream and / or one or more other process streams as feed and / or removing them as products. Element 32: Further includes storing hydrogen and passing the stored hydrogen through a fuel cell to generate electricity to address intermittency in the electricity supply from the renewable IES. Element 33: Further includes producing oxygen and nitrogen in an air separation plant, storing at least a portion of the produced oxygen and / or nitrogen under pressure, and using the pressurized and stored oxygen and / or nitrogen as reactants and / or to generate electricity by expansion when renewable IES are not available and / or above a threshold price.Element 34: Further comprising utilizing one or more dual-use devices to address the availability of electricity from renewable IESs. Element 35: The dual-use devices comprise one or more compressors driven by steam or gas turbines utilized as a backup for one or more electric motor-driven compressors. Element 36: Further comprising utilizing non-renewable electricity as a backup for electricity from renewable IESs when renewable IESs are not available and / or above a threshold price. Element 37: Further comprising powering the electric motor-driven compressors with electricity from renewable IESs when available or below a threshold price, and with non-renewable electricity when renewable IESs are not available and / or above a threshold price. Element 38: Further comprising consuming an average daily amount of at least 25 MW for heating, cooling, compression, or a combination thereof.

[0170] Additional Disclosures Section IV The following are non-limiting specific aspects according to the present disclosure.

[0171] A first embodiment is a method of producing one or more chemical products, comprising: preparing one or more feedstreams comprising one or more reactants for introduction into a reactor; reacting the one or more reactants in the reactor to produce a product stream comprising one or more chemical products; separating the one or more chemical products from reaction by-products, unreacted reactants, or a combination thereof in the product stream, and / or recycling one or more of the unreacted reactants and / or reaction by-products; and, if a renewable intermittent energy source (IES) is available, providing a majority (e.g., greater than 50%, greater than 60%, greater than 70%, greater than 80%, or greater than 90%) of the net energy required for powering, pumping, heating, cooling, compressing, separating, or a combination thereof utilized for one or more of the preparation, reaction, separation, recirculation, or a combination thereof with electricity generated from the renewable intermittent energy source (IES).

[0172] A second embodiment, which is the method of the first embodiment, further comprising compressing at least one stream selected from the one or more feed streams, the one or more chemical products, or at least one intermediate produced by the method, and storing the at least one compressed stream for later use.

[0173] A third embodiment, which is the method of the second embodiment, further comprising expanding at least one stored compressed stream to generate electricity or to perform mechanical work.

[0174] A fourth embodiment, which is the method of the first embodiment, further comprising cooling at least one stream selected from the one or more feed streams, the one or more chemical products, or at least one intermediate produced by the method, and storing the at least one cooled stream for later use.

[0175] A fifth embodiment, which is the method of the fourth embodiment, wherein at least one cooled stream comprises a cryogenic liquid.

[0176] A sixth embodiment, which is the method of the fourth embodiment, wherein the later use comprises use as a refrigerant.

[0177] A seventh embodiment, which is the method of the first embodiment, wherein the preparing, reacting, separating, or a combination thereof produces hydrogen, and the method further comprises converting at least a portion of the produced hydrogen into electricity using a fuel cell.

[0178] An eighth embodiment, which is the method of the seventh embodiment, further comprising storing at least a portion of the produced hydrogen prior to converting at least a portion of the produced hydrogen into electricity using the fuel cell when an intermittent power source is not available.

[0179] A ninth embodiment, which is the method of the seventh embodiment, further comprising compressing the hydrogen before storing it.

[0180] A tenth embodiment, which is the method of the seventh embodiment, further comprising combusting at least a portion of the stored hydrogen to produce water vapor and heat when an intermittent power source is not available, and optionally utilizing the water vapor as a reactant or diluent.

[0181] An eleventh embodiment, which is the method of the first embodiment, further comprising storing energy by increasing the agglomeration when an intermittent power source is available.

[0182] A twelfth embodiment, which is the method of the eleventh embodiment, wherein the agglomeration comprises one or more feeds, one or more products, or water.

[0183] A thirteenth embodiment, which is the method of the first embodiment, wherein the one or more reactors are lined with a refractory material such that a brief loss of power does not cause a temperature drop of more than 10° C. in two minutes of the one or more refractory-lined reactors.

[0184] A fourteenth embodiment, which is the method of the first embodiment, further comprising regulating an inlet pressure of at least one of the one or more feed streams with co-generation of electricity.

[0185] A fifteenth embodiment, which is the method of the first embodiment, further comprising thermally connecting the one or more reactors to the thermal mass such that a brief loss of power does not cause a temperature drop of more than about 5° C. in two minutes of the one or more refractory-lined reactors.

[0186] A sixteenth embodiment, that is the method of the first embodiment, further comprising thermally connecting the one or more reactors to the phase change material such that a brief loss of power does not cause a temperature drop of more than about 4° C. in two minutes of the one or more refractory-lined reactors.

[0187] A seventeenth embodiment, that is the method of the first embodiment, further comprising storing heat (e.g., heated or superheated fluid) for heating one or more process streams when electrical heating from the IES is not available.

[0188] An eighteenth embodiment, which is the method of the first embodiment, further comprising utilizing liquefaction of the phase change material to store energy.

[0189] A nineteenth embodiment, which is the method of the first embodiment, further comprising storing an on-site battery due to intermittency of the electrical supply from the IES.

[0190] A twentieth aspect, which is the method of the first aspect, further comprising providing backup power to the at least one device.

[0191] A twenty-first aspect, which is the method of the twentieth aspect, wherein the backup power device is selected to provide sufficient energy to ensure safe shutdown of the plant.

[0192] A twenty-second embodiment, which is the method of the twentieth embodiment, including providing backup power via a device driven by compressed gas, a capacitor, a superconductor, a thermal battery, and / or a flywheel.

[0193] A twenty-third aspect, which is the method of the first aspect, further comprising operating at least a portion of the plant only if the IES is available.

[0194] A 24th embodiment, which is the method of the first embodiment, further comprising operating at a reduced production rate when no IES is available or a reduced amount of IES is available.

[0195] A 25th embodiment, that is the method of the first embodiment, further comprising receiving information regarding energy prices and availability, and utilizing the information to optimize energy usage, energy storage, and / or production of one or more chemical products.

[0196] A twenty-sixth embodiment, which is a method of operating, designing, and / or improving a chemical synthesis plant, including utilizing electricity from a renewable intermittent energy source (IES) to provide a majority (e.g., greater than 50%, greater than 60%, greater than 70%, greater than 80%, greater than 90%, or greater than 100%) of the net energy required for heating, cooling, compression, or a combination thereof, when the renewable IES is available and / or below a threshold price.

[0197] A twenty-seventh embodiment, that is the method of the twenty-sixth embodiment, further comprising compressing one or more gaseous process streams for storage when renewable IES are available and / or below a threshold price, and utilizing at least a portion of the compressed one or more feed streams as feed streams and / or to provide electrical and / or mechanical work when renewable IES are not available and / or above a threshold price.

[0198] A twenty-eighth embodiment, which is the method of the twenty-seventh embodiment, wherein the one or more gaseous process streams are compressed and stored at a pressure greater than the process operating pressure, and further comprising generating electricity from the pressure reduction from the pressure greater than the process operating pressure to the operating pressure.

[0199] A twenty-ninth embodiment, which is the method of the twenty-seventh embodiment, wherein the one or more gaseous process streams are compressed and liquefied when electricity from renewable IESs is available and / or below a threshold price, and vaporized and expanded to produce electricity, perform mechanical work, and / or provide a supply when electricity from renewable IESs is not readily available and / or above a threshold price.

[0200] A thirtieth embodiment, which is the method of the twenty-sixth embodiment, further comprising cooling and storing the product stream and / or one or more process streams for use as a refrigerant for intermittent electricity supply from the renewable IES.

[0201] A thirty-first embodiment, which is the method of the thirtieth embodiment, wherein the product stream and / or one or more process streams comprise methane, ethane, propane, ethylene, propylene, ammonia, or a combination thereof.

[0202] A thirty-second embodiment, which is the method of the thirtieth embodiment, wherein the product stream and / or one or more process streams are cooled and stored when electricity from the renewable IES is readily available and / or below a threshold price, and used to cool one or more other process streams when electricity from the renewable IES is not available and / or above a threshold price, thereby producing one or more relatively warm liquid and / or gas streams.

[0203] A thirty-third embodiment, which is the method of the thirty-second embodiment, further comprising utilizing as feed and / or removing as product one or more relatively warm liquid and / or gas streams obtained by cooling the product stream and / or one or more other process streams.

[0204] A thirty-fourth embodiment, which is the method of the twenty-sixth embodiment, further comprising storing hydrogen and passing the stored hydrogen through a fuel cell to generate electricity to address intermittency of the electricity supply from the renewable IES.

[0205] A thirty-fifth embodiment, that is the method of the twenty-sixth embodiment, further comprising producing oxygen and nitrogen in an air separation plant, storing at least a portion of the produced oxygen and / or nitrogen under pressure, and utilizing the pressurized and stored oxygen and / or nitrogen as reactants and / or to generate electricity by expansion when renewable IES are not available and / or above a threshold price.

[0206] A thirty-sixth embodiment, which is the method of the twenty-sixth embodiment, further comprising utilizing one or more dual devices to address the availability of electricity from renewable IESs.

[0207] A thirty-seventh embodiment, which is the method of the thirty-sixth embodiment, wherein the dual apparatus comprises one or more compressors driven by steam or gas turbines utilized as backups for one or more electric motor-driven compressors.

[0208] A thirty-eighth embodiment, which is the method of the twenty-sixth embodiment, further comprising utilizing non-renewable electricity as a backup for electricity from the renewable IES when the renewable IES is not available and / or exceeds a threshold price.

[0209] A thirty-ninth embodiment, which is the method of the thirty-eighth embodiment, further comprising powering the electric motor driven compressor with electricity from renewable IES when available or below a threshold price, and with non-renewable electricity when renewable IES are not available and / or above a threshold price.

[0210] A fortieth embodiment, which is the method of the twenty-sixth embodiment, further comprising consuming an average daily amount of at least 25 MW for heating, cooling, compression, or a combination thereof.

[0211] A forty-first embodiment, which is a method of operating a chemical process described herein.

[0212] Additional Disclosures Section V The following are non-limiting specific aspects according to the present disclosure.

[0213] A first embodiment is a chemical synthesis plant comprising: one or more reactors configured to produce a process stream from one or more reactants, the process stream comprising at least one chemical product; a feed preparation system configured to prepare one or more feed streams comprising one or more of the one or more reactants for introduction to the reactors; and a product purification system configured to separate the at least one chemical product from reaction by-products, unreacted reactants, or a combination thereof in the process stream; wherein the chemical synthesis plant is configured such that at least 50% of the net energy required for heating, cooling, compression, or a combination thereof utilized via the one or more reactors, the feed preparation system, the product purification system, or a combination thereof is supplied from an intermittent energy source (IES), and the plant consumes an average daily amount of at least 25 MW of electricity for heating, cooling, compression, or a combination thereof.

[0214] A second embodiment, which is the chemical synthesis plant according to the first embodiment, wherein the chemical synthesis plant does not include a flue gas heat recovery section.

[0215] A third embodiment, which is the chemical synthesis plant according to the first embodiment, further comprising one or more compressors configured to compress at least one stream comprising one or more of said reactants, at least one of said chemical products, or at least one intermediate produced by said process, a storage device configured to store at least one compressed stream for later use, and further comprising a device for expanding at least one stored compressed stream to generate electricity or to perform mechanical work.

[0216] A fourth embodiment, which is the chemical synthesis plant according to the first embodiment, further comprising: a cooling device configured to cool at least one stream selected from one or more of said reactants, at least one of said chemical products, or at least one intermediate produced by said method; and a storage device configured to store at least one cooled stream for later use, wherein at least one cooled stream comprises a cryogenic liquid.

[0217] A fifth embodiment, which is the chemical synthesis plant according to the first embodiment, wherein the one or more reactors, feed preparation system, product purification system, or combination thereof are configured for production of hydrogen; the chemical synthesis plant further comprises a fuel cell for converting at least a portion of the produced hydrogen into electricity; the chemical synthesis plant further comprises a hydrogen storage device for storing at least a portion of the produced hydrogen prior to converting at least a portion of the produced hydrogen into electricity using the fuel cell when an intermittent power source is not available; and a compressor upstream of the hydrogen storage device, the compressor configured to compress the hydrogen prior to storing the hydrogen.

[0218] A sixth embodiment, which is the chemical synthesis plant according to the first embodiment, wherein the one or more reactors, feed preparation system, product purification system, or combination thereof are configured for production of hydrogen; the chemical synthesis plant further comprises a hydrogen storage device and a compressor upstream of the hydrogen storage device, the compressor configured to compress at least a portion of the produced hydrogen before storage; and the chemical synthesis plant further comprises a combustion device for combusting a portion of the stored hydrogen to produce steam or heat when intermittent power is not available, wherein the steam is used as a reactant or diluent.

[0219] A seventh embodiment, which is a chemical synthesis plant according to the first embodiment, further comprising an apparatus for storing energy by growing an agglomeration when an intermittent power source is available, the agglomeration comprising one or more feeds, one or more products, or water.

[0220] An eighth embodiment, which is a chemical synthesis plant according to the first embodiment, wherein the one or more reactors are lined with a refractory material such that a brief loss of power does not cause a temperature drop of more than about 10° C. in 2 minutes of the one or more refractory-lined reactors.

[0221] A ninth embodiment, which is a chemical synthesis plant according to the first embodiment, wherein the one or more reactors are thermally connected to the thermal mass such that a brief loss of power does not cause a significant temperature drop of more than about 5°C over 2 minutes in the one or more refractory-lined reactors.

[0222] A tenth embodiment, which is a chemical synthesis plant according to the first embodiment, wherein the one or more reactors are thermally connected to the phase change material such that a brief loss of power does not cause a temperature drop of more than about 4°C in 2 minutes in the one or more refractory-lined reactors.

[0223] An eleventh aspect, which is a chemical synthesis plant according to the first aspect, further comprising an apparatus operable to store heat as a heated or superheated fluid for heating one or more process streams when an IES is not available.

[0224] A twelfth aspect, a chemical synthesis plant according to the first aspect, further comprising an apparatus configured to utilize liquefaction of a phase change material to store energy.

[0225] A thirteenth aspect, which is a chemical synthesis plant according to the first aspect, further comprising a backup power device configured to supply backup power to at least one device of the chemical synthesis plant, the backup power device being selected to provide sufficient energy to ensure safe shutdown of the plant, and the backup power device comprising a device powered by compressed gas, a capacitor, a superconductor, a thermal battery, and / or a flywheel.

[0226] A fourteenth aspect, which is the chemical synthesis plant according to the first aspect, further comprising a system for receiving information regarding energy prices and availability, whereby this information can be utilized to optimize energy usage, energy storage, and plant operation.

[0227] A fifteenth aspect, which is a chemical synthesis plant according to the first aspect, further comprising: an air separation unit (ASU) configured to produce oxygen and nitrogen, a storage device configured to store at least a portion of the produced oxygen and / or nitrogen under pressure, and an expander, such that the pressurized and stored oxygen and / or nitrogen may be utilized as reactants and / or utilized to generate electricity by expansion in the expander when an IES is not available and / or exceeds a threshold price.

[0228] A sixteenth embodiment is a method of producing one or more chemical products, comprising: preparing one or more feed streams comprising one or more reactants for introduction into a reactor; reacting the one or more reactants in the reactor to produce a product stream comprising one or more chemical products; separating the one or more chemical products from reaction by-products, unreacted reactants, or a combination thereof in the product stream; recirculating one or more of the unreacted reactants and / or reaction by-products; and, if a renewable intermittent energy source (IES) is available, providing at least 50% of the net energy required for powering, pumping, heating, cooling, compression, separation, or a combination thereof utilized for one or more of the preparation, reaction, separation, recirculation, or a combination thereof with electricity generated from the renewable intermittent energy source (IES), wherein the plant consumes an average daily amount of at least 25 MW of electricity for heating, cooling, compression, or a combination thereof.

[0229] While preferred embodiments of the present invention have been shown and described, modifications thereof can be made by those skilled in the art without departing from the teachings of this disclosure. The embodiments described herein are illustrative only and are not intended to be limiting. Many variations and modifications of the invention disclosed herein are possible and are within the scope of the invention.

[0230] Once the above disclosure is fully understood, numerous other modifications, equivalents, and alternatives will become apparent to those skilled in the art. The appended claims are intended to be construed to encompass all such modifications, equivalents, and alternatives, where applicable. Accordingly, the scope of protection is not limited by the above description, but is limited only by the appended claims, which scope includes all equivalents of the subject matter of the claims. Each and every claim is incorporated herein as an embodiment of the present invention. Accordingly, the claims are further explanation and additions to the detailed description of the present invention. The disclosures of all patents, patent applications, and publications cited herein are incorporated herein by reference.

Claims

1. one or more reactors configured to produce, from one or more hydrocarbon feed streams comprising one or more reactants, a process stream comprising at least one chemical product selected from the list of chemical products consisting of ammonia, methanol, ethylene, propylene, ethylene oxide, monoethylene glycol, ethylene dichloride, vinyl chloride, α-olefins, isoparaffins, ethylbenzene, phenol, terephthalic acid, MTBE, polyethylene (PE), polypropylene (PP), polyvinyl chloride (PVC), polystyrene (PS), polycarbonate (PC), polyethylene terephthalate (PET), acetic acid, vinyl acetate, acrylic acid, methacrolein, methyl methacrylate, acrylonitrile, sulfuric acid, nitric acid, propylene glycol, adipic acid, caprolactam, cyclohexanone, 1,6 diaminohexane, polyvinyl alcohol (PVA), polyacrylate, polymethyl methacrylate (PMMA), and nylon; a feed preparation system configured to prepare the one or more hydrocarbon feed streams comprising one or more of the one or more reactants for introduction into the reactor; and a product purification system configured to separate the at least one chemical product from reaction by-products, unreacted reactants, or combinations thereof in the process stream. A chemical synthesis plant comprising: the chemical synthesis plant is configured such that at least 50% of the net energy required for heating, cooling, compression, or a combination thereof utilized via one or more of the reactors, the feed preparation system, the product purification system, or a combination thereof, is supplied from renewable energy sources, wherein the net energy is energy that results in primary energy consumption; the plant consumes an average daily amount of at least 25 MW of electricity for the heating, cooling, compression, or combination thereof; The chemical synthesis plant.

2. 10. The chemical synthesis plant of claim 1, which does not include a flue gas heat recovery section.

3. one or more compressors configured to compress gas flowing through the chemical synthesis plant, including one or more of the reactants, at least one of the chemical products, or at least one intermediate produced by the process; a storage device configured to store the compressed gas for later use. Furthermore, Apparatus for expanding said stored compressed gas to generate electricity or to perform mechanical work.

10. The chemical synthesis plant of claim 1, further comprising:

4. a cooling device configured to cool gases flowing through the chemical synthesis plant, including one or more of the reactants, at least one of the chemical products, or at least one intermediate produced by the process; and a storage device configured to store the cooled gas for later use. Furthermore, the cooled gas comprises a cryogenic liquid; The chemical synthesis plant of claim 1.

5. one or more reactors, feed preparation systems, product purification systems, or combinations thereof, are configured for the production of hydrogen; the chemical synthesis plant further comprising a fuel cell for converting at least a portion of the produced hydrogen into electricity; The chemical synthesis plant a hydrogen storage device for storing at least a portion of the produced hydrogen prior to converting at least a portion of the produced hydrogen into electricity using the fuel cell when an intermittent power source is not available. Furthermore, a compressor upstream of the hydrogen storage device configured to compress the hydrogen before storing the hydrogen; Further provided with The chemical synthesis plant of claim 1.

6. 10. The chemical synthesis plant of claim 1, wherein the one or more reactors, feed preparation system, product purification system, or combination thereof are configured for the production of hydrogen; wherein the chemical synthesis plant further comprises a hydrogen storage device and a compressor upstream of the hydrogen storage device, the compressor configured to compress at least a portion of the produced hydrogen before storage; and wherein the chemical synthesis plant further comprises a combustion device for combusting a portion of the stored hydrogen to produce steam or heat when an intermittent power source is not available, the steam being used as a reactant or diluent.

7. 10. The chemical synthesis plant of claim 1, further comprising an apparatus for storing energy by expanding a liquid or solid when an intermittent power source is available, the liquid or solid comprising one or more feeds, one or more products, or water.

8. 10. The chemical synthesis plant of claim 1, wherein the one or more reactors are lined with a refractory material such that a brief loss of power does not cause a temperature drop of more than 10° C. in two minutes in the one or more refractory-lined reactors.

9. 10. The chemical synthesis plant of claim 1, wherein the one or more reactors are thermally connected to the main body such that a brief loss of power does not cause a significant temperature drop of more than 5°C in two minutes in the one or more refractory-lined reactors.

10. 10. The chemical synthesis plant of claim 1, wherein one or more reactors are thermally connected to a phase change material that can change from one phase to another such that a brief loss of power does not cause a temperature drop of more than 4°C in two minutes in the one or more refractory-lined reactors.

11. 10. The chemical synthesis plant of claim 1, further comprising a device operable to store heat as a heated or superheated fluid for heating one or more process streams when a renewable energy source is not available.

12. 10. The chemical synthesis plant of claim 1, further comprising an apparatus configured to utilize liquefaction of a phase change material capable of changing from one phase to another to store energy.

13. 10. The chemical synthesis plant of claim 1, further comprising a backup power device configured to provide backup power to at least one device of the chemical synthesis plant, the backup power device selected to provide sufficient energy to ensure safe shutdown of the plant, the backup power device comprising a device powered by compressed gas, a capacitor, a superconductor, a thermal battery, and / or a flywheel.

14. 10. The chemical synthesis plant of claim 1, further comprising a system for receiving information regarding energy prices and availability, whereby this information can be utilized to optimize energy usage, energy storage, and plant operation.

15. When renewable energy sources are not available and / or above a threshold price, pressurized stored oxygen and / or nitrogen may be utilized as reactants and / or to generate electricity by expansion in an expander; an air separation unit (ASU) configured to produce oxygen and nitrogen; a storage device configured to store under pressure at least a portion of the produced oxygen and / or nitrogen; Expander and 10. The chemical synthesis plant of claim 1, further comprising:

16. preparing one or more hydrocarbon feed streams comprising one or more reactants for introduction into the reactor; reacting the one or more reactants in the reactor to produce a product stream comprising one or more chemical products; separating the one or more chemical products from reaction by-products, unreacted reactants, or combinations thereof within the product stream; recycling one or more of the unreacted reactants and / or reaction by-products; and providing at least 50% of the net energy required for powering, pumping, heating, cooling, compressing, separating, or a combination thereof utilized for one or more of said preparing, said reacting, said separating, said recycling, or a combination thereof, with electricity generated from renewable energy sources, if such sources are available; 10. A method for producing one or more chemical products in a chemical synthesis plant according to claim 1, comprising: the plant consumes an average daily amount of at least 25 MW of electricity for said heating, cooling, compression, or combination thereof; The method.

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