Simultaneous production of hydrogen, carbon, electricity and concrete with carbon dioxide capture

Abstract

A hydrocarbon feed stream is exposed to heat in the absence of oxygen, converting the hydrocarbon feed stream into a solids stream and a gas stream. The gas stream is separated into an exhaust gas stream and hydrogen. Carbon is separated from the solids stream as a carbon stream. A water stream is subjected to electrolysis to produce an oxygen stream and hydrogen. The oxygen and a portion of the carbon are combined to generate electricity and a carbon dioxide stream. At least a portion of the carbon stream, cement, and water are mixed to form a concrete mix. The concrete mix can be used to produce ready-mix and precast concrete. The carbon dioxide used to cure the concrete can be sourced from a carbon dioxide stream produced by generating electricity.

Description

[Technical Field]

[0001] (Related Applications) This application claims the benefit of priority to U.S. Patent Application No. 18 / 077,643, filed December 8, 2022, the contents of which are incorporated herein by reference in their entirety.

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

[0003] Carbon is an abundant element in the Earth's crust. Carbon's abundance, diversity in the makeup of organic compounds, and ability to form polymers at temperatures commonly found on Earth make it the common element for all known life. Carbon atoms can bond in a variety of ways, resulting in various carbon allotropes. Some examples of carbon allotropes include graphite, diamond, amorphous carbon, carbon nanotubes, carbon fiber, and fullerenes. The physical properties of carbon vary significantly between allotropes. As such, carbon is widely used at or near commercial scales in a variety of markets.

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

[0005] In the global effort to reduce carbon emissions, there has been growing interest in the energy transition from fossil fuels to renewable and sustainable energy. Examples of decarbonization pathways in the energy transition to renewable energy include improved energy efficiency, the production and / or use of low-carbon fuels, and carbon capture and storage (CCS). Summary of the Invention

[0006] The present disclosure relates to techniques for the simultaneous production of hydrogen, carbon, power, and concrete, while generating sequesterable carbon dioxide. Certain aspects of the disclosed subject matter can be implemented as a method. A hydrocarbon feed stream is exposed to heat in the absence of oxygen to convert the hydrocarbon feed stream into a solids stream and a gas stream. The hydrocarbon feed stream includes hydrocarbons. The solids stream includes carbon. The gas stream includes hydrogen. The gas stream is separated from an exhaust gas stream and a first hydrogen stream. The first hydrogen stream includes at least a portion of the hydrogen from the gas stream. Carbon from the solids stream is separated to produce a carbon stream. Electrolysis is performed on a water stream to produce an oxygen stream and a second hydrogen stream. The water stream includes water. The oxygen stream includes oxygen. The second hydrogen stream includes hydrogen. At least a portion of the oxygen from the oxygen stream reacts with a first portion of the carbon from the carbon stream to produce power and a carbon dioxide stream. The carbon dioxide stream includes carbon dioxide. The first portion of the generated power is used to perform electrolysis on the water stream. A second portion of the carbon stream is mixed with a cement stream and water to form a concrete mix. The cement stream includes cement. In some embodiments, aggregate is mixed into the concrete mix. A first portion of the carbon dioxide stream is pressurized using a second portion of the generated electrical power to form a pressurized carbon dioxide stream. The pressurized carbon dioxide stream is in a liquefied or supercritical state. In some embodiments, the pressurized carbon dioxide stream is in a liquefied state. In some embodiments, the pressurized carbon dioxide stream is in a supercritical state. The pressurized carbon dioxide stream is discharged. The first portion of the concrete mix is ​​discharged as a ready-mix concrete stream. A second portion of the concrete mix is ​​cured using the second portion of the carbon dioxide stream to produce a precast concrete stream. In some embodiments, at least a portion of the generated electrical power is used for another process requiring heat and / or electricity, either on-site or off-site.

[0007] This and other embodiments may include one or more of the following features. The hydrocarbon feed stream may include one or more C1-C22 alkanes, one or more C1-C22 alkenes, or any combination thereof. The hydrocarbon feed stream may include hydrogen. Oxygen and carbon may be combined, for example, by a direct carbon fuel cell (DCFC) including a solid oxide fuel cell. Oxygen and carbon may be combined by a direct carbon fuel cell at an operating temperature ranging from about 550°C to about 900°C. Heat may be transferred from the gas stream to a buffer fluid by a first heat recovery heat exchanger. Prior to exposing the hydrocarbon feed stream to heat in the absence of oxygen, heat may be transferred from the buffer fluid to the hydrocarbon feed stream by a second heat recovery heat exchanger. The heat transferred from the gas stream to the buffer fluid may be used to generate power using a Rankine cycle. Power generation using a Rankine cycle may include transferring heat from the buffer fluid to a working fluid in a boiler and vaporizing the working fluid to form a vaporized working fluid. Power generation using a Rankine cycle can include flowing and expanding a vaporized working fluid through a turbine to generate electricity. Power generation using a Rankine cycle can include condensing the vaporized working fluid into a condensed working fluid. Power generation using a Rankine cycle can include circulating the condensed working fluid to a boiler. Heat can be transferred from the carbon dioxide stream to the buffer fluid by a first waste heat recovery heat exchanger. Heat can be transferred from the buffer fluid to the hydrocarbon feed stream by a second waste heat recovery heat exchanger before exposing the hydrocarbon feed stream to heat in the absence of oxygen. After curing the second portion of the concrete mix to produce a precast concrete stream, the remainder of the carbon dioxide stream can be flowed to a ready-mix concrete production unit to, for example, facilitate the formation of the concrete mix. The carbon dioxide stream produced by the direct carbon fuel cell and the carbon dioxide produced by smelting alumina can be sequestered in underground geological formations to prevent the carbon dioxide stream and carbon dioxide from being released into the atmosphere.

[0008] Certain aspects of the disclosed subject matter can be implemented as a system. The system includes a hydrocarbon feed stream, a pyrolysis chamber, a gas separation unit, a carbon separation unit, a water stream, an electrolysis unit, a power generation unit, a cement stream, a ready-mix concrete production unit, and a precast concrete production unit. The hydrocarbon feed stream includes hydrocarbons. The pyrolysis chamber is configured to receive the hydrocarbon feed stream and expose the hydrocarbon feed stream to heat in the absence of oxygen to convert the hydrocarbon feed stream into a solids stream and a gas stream. The solids stream includes carbon. The gas stream includes hydrogen. The gas separation unit is configured to receive the gas stream from the pyrolysis chamber and separate hydrogen from the gas stream to produce an exhaust gas stream and a first hydrogen stream. The first hydrogen stream includes at least a portion of the hydrogen from the gas stream. The carbon separation unit is configured to receive the solids stream from the pyrolysis chamber and separate carbon from the solids stream to produce a carbon stream. The water stream includes water. The electrolysis unit is configured to receive the water stream and electrical power. The electrolysis unit is configured to perform electrolysis on the water stream using the electrical power to produce an oxygen stream and a second hydrogen stream. The oxygen stream comprises oxygen. The second hydrogen stream comprises hydrogen. The power generation unit is configured to receive at least a portion of the oxygen stream from the electrolysis unit and a first portion of the carbon stream from the carbon separation unit. The power generation unit may comprise, for example, a direct carbon fuel cell. The direct carbon fuel cell is configured to combine oxygen from a portion of the oxygen stream and carbon from a portion of the carbon stream to generate electrical power and a carbon dioxide stream. The carbon dioxide stream comprises carbon dioxide. A first portion of the electrical power generated by the power generation unit is provided to the electrolysis unit to perform electrolysis on a water stream. The cement stream comprises cement. The ready-mix concrete production unit is configured to receive the cement stream and the second portion of the carbon stream. The ready-mix concrete production unit is configured to mix the cement stream, the second portion of the carbon stream, and water to form a concrete mix. In some embodiments, aggregate is mixed into the concrete mix. The ready-mix concrete production unit is configured to receive a first portion of the carbon dioxide stream from the power generation unit and a second portion of the electrical power generated by the power generation unit.The ready mixed concrete production unit is configured to pressurize a first portion of the carbon dioxide stream using a second portion of the electrical power generated by the power generation unit to form a high-pressure carbon dioxide stream. The high-pressure carbon dioxide stream is in a liquefied or supercritical state. The ready mixed concrete production unit is configured to discharge the high-pressure carbon dioxide stream. The ready mixed concrete production unit is configured to discharge the first portion of the concrete mix as a ready mixed concrete stream. The precast concrete production unit is configured to receive a second portion of the concrete mix from the ready mixed concrete production unit and a second portion of the carbon dioxide stream from the power generation unit. The precast concrete production unit is configured to use the second portion of the carbon dioxide stream to harden the second portion of the concrete mix to produce a precast concrete stream.

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

[0010] The details of one or more embodiments of the presently disclosed subject matter are set forth in the accompanying drawings and description. Other features, aspects, and advantages of the present subject matter will become apparent from the description, drawings, and claims. [Brief explanation of the drawings]

[0011] [Figure 1A] 1 is a schematic diagram of an exemplary system for the simultaneous production of hydrogen, carbon, power and concrete. [Figure 1B] FIG. 1B is a schematic diagram of an exemplary pyrolysis chamber that can be implemented in the system of FIG. 1A. [Figure 1C] FIG. 1B is a schematic diagram of example components that may be included in the gas separation unit of the system of FIG. 1A. [Figure 1D] FIG. 1B is a schematic diagram of example components that may be included in the carbon separation unit of the system of FIG. 1A. [Figure 1E] FIG. 1B is a schematic diagram of an exemplary electrolysis unit that can be implemented in the system of FIG. 1A. [Figure 1F] FIG. 1B is a schematic diagram of an exemplary direct carbon fuel cell (DCFC) that can be implemented in the system of FIG. 1A. [Figure 1G] 1 is a schematic diagram of an exemplary system for the co-production of hydrogen, carbon, power and concrete with waste heat recovery. [Figure 1H] 1 is a schematic diagram of an exemplary system for the co-production of hydrogen, carbon, power and concrete with waste heat recovery. [Figure 2] FIG. 1 is a schematic diagram of an example of a Rankine cycle that uses heat to generate electricity. [Figure 3] FIG. 1 is a flow diagram of an exemplary process for the simultaneous production of hydrogen, carbon, power, and concrete. DETAILED DESCRIPTION OF THE INVENTION

[0012] This disclosure describes a system for the simultaneous production of hydrogen, oxygen, carbon, carbon dioxide, electricity, and concrete. The three main feedstocks to the system are a hydrocarbon stream, a water stream, and cement. In some implementations, renewable electricity and / or electricity from the grid is used as needed. The hydrocarbon stream is pyrolyzed to produce solid carbon and hydrogen. The water stream is separated by electrolysis to produce oxygen and hydrogen. Electricity can be generated by (i) burning carbon (e.g., obtained from pyrolysis of a hydrocarbon stream) in the presence of oxygen (obtained from electrolysis of a water stream) to generate heat that can be used to generate steam for a steam turbine; (ii) combining carbon (obtained from pyrolysis of a hydrocarbon stream) and oxygen (obtained from electrolysis of a water stream) using a direct carbon fuel cell (DCFC); or both (i) and (ii). The cement, carbon, and at least a portion of the electricity are used to produce concrete and other solid carbon-based products. In some implementations, waste heat recovery is performed for process integration and efficiency optimization. At least a portion of the carbon dioxide produced by the system is captured and used to cure precast and / or ready-mix concrete.

[0013] The subject matter described herein can be implemented in certain embodiments to realize one or more of the following advantages: Carbon dioxide, which may be produced as a by-product, can be sequestered and / or utilized in another industrial process rather than released to the atmosphere. The system is flexible and can accept a wide range of feedstocks, such as traditional hydrocarbons (e.g., natural gas, crude oil, and / or their derivatives), biogas, bioliquid fuels, or petroleum waste. The system described herein can be implemented to address supply intermittencies of renewable energy sources while utilizing excess solid carbon products from pyrolysis that are difficult to market. For example, a portion of the carbon produced by the system can be used as an energy storage medium, and another portion of the carbon produced by the system can be marketed as a feedstock for another industrial process. For example, the carbon produced by the system can be used to produce carbon black, synthetic graphite, carbon filaments / fibers, and / or carbon nanostructures (e.g., carbon nanotubes and carbon nanofibers). For example, at least a portion of the carbon produced by the system can be used to generate electricity. At least a portion of the carbon dioxide produced by the system can be used to manufacture concrete. The remainder of the carbon dioxide produced by the system is sequestration-ready, in the sense that it can be transported (e.g., by pipeline) for sequestration in the Earth's subsurface layers, rather than being released into the atmosphere and contributing to carbon emissions.

[0014] FIG. 1A is a schematic diagram of an exemplary system 100 for the simultaneous production of hydrogen, carbon, and electricity for concrete production. System 100 includes a hydrocarbon feed stream 101. Hydrocarbon feed stream 101 includes hydrocarbons (e.g., alkanes, alkenes, alkynes, cyclic hydrocarbons, aromatic hydrocarbons, and / or non-aromatic hydrocarbons). In some embodiments, hydrocarbon feed stream 101 includes a plurality of hydrocarbons selected from C1-C22 alkanes (i.e., alkanes having 1 to 22 carbon atoms) and / or C1-C22 alkenes (i.e., alkenes having 1 to 22 carbon atoms). In some embodiments, hydrocarbon feed stream 101 includes components other than hydrocarbons, such as hydrogen. However, hydrocarbon feed stream 101 does not include any oxygen-containing components. System 100 includes a water stream 103 that includes water (i.e., HO).

[0015] System 100 includes a pyrolysis chamber 110, a gas separation unit 120, a carbon separation unit 130, an electrolysis unit 140, a power generation unit 150, a ready-mix concrete production unit 170A, and a precast concrete production unit 170B. Pyrolysis chamber 110 is configured to receive a hydrocarbon feed stream 101. Pyrolysis chamber 110 exposes the hydrocarbon feed stream 101 to heat in the absence of oxygen to convert the hydrocarbon feed stream 101 into a solids stream 105 and a gas stream 107. In some embodiments, depending on the composition of the hydrocarbon feed stream 101, pyrolysis chamber 110 also produces liquids (e.g., bio-oil), which are discharged from pyrolysis chamber 110 along with solids stream 105. Solids stream 105 includes carbon. Gas stream 107 includes hydrogen. In some embodiments, gas stream 107 includes carbon (e.g., small particles entrained in gas stream 107), unconverted hydrocarbons from the hydrocarbon feed stream 101, or both. In some embodiments, the pyrolysis chamber 110 is configured to pyrolyze the hydrocarbon feed stream 101 without the use of a catalyst (non-catalytic pyrolysis). In some embodiments, the pyrolysis chamber 110 is configured to pyrolyze the hydrocarbon feed stream 101 using a catalyst (catalytic pyrolysis).

[0016] The gas separation unit 120 is configured to receive the gas stream 107 from the pyrolysis chamber 110. The gas separation unit 120 is configured to separate hydrogen from the gas stream 107 to produce an exhaust gas stream 109 and a first hydrogen stream 111. The first hydrogen stream 111 comprises at least a portion of the hydrogen from the gas stream 107. In some embodiments, the first hydrogen stream 111 comprises substantially all of the hydrogen from the gas stream 107. In some embodiments, the exhaust gas stream 109 is the remainder of the gas stream 107 minus the first hydrogen stream 111. For example, the exhaust gas stream 109 may comprise a relatively small portion of the hydrogen from the gas stream 107 compared to the first hydrogen stream 111. In some embodiments, the exhaust gas stream 109 may comprise unconverted hydrocarbons from the hydrocarbon feed stream 101, and therefore at least a portion of the exhaust gas stream 109 is recycled back to the pyrolysis chamber 110. In some embodiments, at least a portion of the first hydrogen stream 111 is stored and / or transported for use in another industrial process, such as ammonia production, power generation, feedstock for hydrogen fuel cells, hydrocarbon sweetening processes, petroleum refining, metal processing (e.g., steelmaking), fertilizer production, food processing, etc.

[0017] Carbon separation unit 130 is configured to receive solids stream 105 from pyrolysis chamber 110. Carbon separation unit 130 is configured to separate carbon from solids stream 105 to produce carbon stream 113. For example, if solids stream 105 includes a liquid, carbon separation unit 130 separates carbon from the liquid to produce carbon stream 113. Carbon stream 113 may include carbon black, charcoal, synthetic graphite, carbon filaments / fibers, and / or carbon nanostructures (e.g., carbon nanotubes and carbon nanofibers), or any combination thereof. In some embodiments, at least a portion of carbon stream 113 is stored or transported for use in another industrial process, such as power generation, tire manufacturing, battery manufacturing, wind blade manufacturing, or electronics manufacturing. In some embodiments, at least a portion of carbon stream 113 is sold to an external market. In some embodiments, carbon separation unit 130 is configured to process carbon stream 113. For example, the carbon separation unit 130 may crush, crush, and / or mill the carbon stream 113 to adjust the physical characteristics (such as average particle size) of the carbon stream 113 before or after separation depending on the desired application.

[0018] Electrolysis unit 140 is configured to receive water stream 103 and electrical power. Electrolysis unit 140 uses the received electrical power to perform electrolysis on water stream 103 to produce oxygen stream 115 and second hydrogen stream 117. Oxygen stream 115 comprises oxygen. At least a portion of oxygen stream 115 (e.g., all of oxygen stream 115) is input to power generation unit 150 for power generation. In some embodiments, at least a portion of oxygen stream 115 is stored and / or transported for use in fuel combustion, power generation, or another industrial process, e.g., located elsewhere, where oxygen may be utilized. Second hydrogen stream 117 comprises hydrogen. In some embodiments, at least a portion of second hydrogen stream 117 is stored and / or transported for use in another industrial process, e.g., ammonia production, power generation, feedstock for hydrogen fuel cells, hydrocarbon sweetening, petroleum refining, metal processing (e.g., steelmaking), fertilizer production, and food processing. In some embodiments, at least a portion of the first hydrogen stream 111 and at least a portion of the second hydrogen stream 117 are combined, stored, and / or transported for use in another industrial process, such as ammonia production, power generation, feedstock for hydrogen fuel cells, hydrocarbon sweetening, petroleum refining, metal processing (e.g., steelmaking), fertilizer production, and food processing. The electrolysis unit 140 can be configured to receive power from a variety of power sources. For example, the electrolysis unit 140 can be configured to receive power from a renewable energy source. For example, the electrolysis unit 140 can be configured to receive power from a power grid. For example, the electrolysis unit 140 can be configured to receive power from the power generation unit 150. For example, the electrolysis unit 140 can be configured to receive power from a Rankine cycle (an example of which is shown in FIG. 2 and described in more detail below). The electrolysis unit 140 can be configured to switch between multiple power sources based on the available power from the various power sources and the demand for power.

[0019] The power generation unit 150 is configured to receive at least a portion of the oxygen stream 115 from the electrolysis unit 140 (e.g., most or all of the oxygen stream 115) and at least a portion of the carbon stream 113 from the carbon separation unit 130. In some embodiments, the power generation unit 150 includes a direct carbon fuel cell (DCFC) 151. The direct carbon fuel cell 151 is configured to combine oxygen from some (or all) of the oxygen stream 115 with carbon from some (or all) of the carbon stream 113 to produce electricity and a carbon dioxide stream 119. The carbon dioxide stream 119 includes carbon dioxide. The carbon dioxide stream 119 produced by the direct carbon fuel cell 151 is a high-purity carbon dioxide stream. For example, the carbon dioxide stream 119 includes at least 99 vol% (volume percent) or at least 99.9 vol% carbon dioxide. For example, the carbon dioxide stream 119 is pure carbon dioxide. The electricity generated by the power generation unit 150 can be distributed by a power distribution unit 160, which is described in more detail below. At least a portion of the electricity generated by power generation unit 150 is provided to electrolysis unit 140 to perform the electrolysis of water stream 103. In some embodiments, at least a portion of carbon dioxide stream 119 (e.g., most or all of carbon dioxide stream 119) is transported (e.g., via a pipeline) for industrial use and / or sequestered, for example, in a subsurface formation of the Earth. The subsurface formation may be a geological formation within the Earth that forms a reservoir, or in other examples, may be multiple geological formations or a portion of a single geological formation. The subsurface formation may include, for example, a single geological formation, a portion of a single geological formation, or multiple geological formations within a reservoir. In some embodiments, the subsurface formation includes a subsurface formation of naturally fractured or porous rock. In some embodiments, the subsurface formation may intersect with other types of geological formations, including reservoirs that are not naturally fractured. In some embodiments, at least a portion of carbon dioxide stream 119 is stored and / or transported for use in another industrial process, such as cement production. In some embodiments, at least a portion of the carbon dioxide stream 119 is injected into a subterranean formation to enhance the recovery of hydrocarbons from the formation.The carbon dioxide stream 119 is not released into the atmosphere and therefore does not contribute to greenhouse gas emissions.

[0020] The power generation unit 150 may include additional and / or alternative components apart from the direct carbon fuel cell 151 for generating electricity. In some embodiments, the power generation unit 150 includes a combustion chamber (not shown) in which carbon (fuel) from some (or all) of the carbon stream 113 is combusted in the presence of oxygen (oxidant) from some (or all) of the oxygen stream 115. In such embodiments, heat is generated as the carbon is oxidized to carbon dioxide. The heat from combustion can be used in a Rankine cycle (e.g., including a turbine) to generate electricity (an example is shown in FIG. 2 and described in more detail below). For example, the heat from combustion can be used in a boiler to generate steam for a steam turbine to generate electricity. Waste heat can be recovered, for example, to heat other process streams in the system (e.g., the hydrocarbon feed stream 101) and / or to generate electricity, for example, via a Rankine cycle.

[0021] Ready-mix concrete production unit 170A is configured to receive cement stream 170′ and at least a portion of carbon stream 113 from carbon separation unit 130. Ready-mix concrete production unit 170A is configured to mix cement stream 170′, a portion of carbon stream 113, and water (e.g., water stream 103 or a portion of a different water stream) to produce concrete mix 170″. In some embodiments, aggregate (comprising geological materials such as gravel, sand, crushed stone, etc.) is mixed with cement stream 170′, a portion of carbon stream 113, and water to form concrete mix 170″. In some embodiments, additives (such as fly ash) are added to concrete mix 170″. In some embodiments, concrete mix 170″ includes about 1 wt% (weight percent) to about 10 wt% carbon from carbon stream 113. In some embodiments, concrete mixture 170″ includes greater than about 10 wt% carbon from carbon stream 113. The carbon content of concrete mixture 170″ may depend on the amount of nanoparticles present in carbon stream 113 (obtained from the pyrolysis of hydrocarbon feed stream 101).

[0022] Ready-mix concrete production unit 170A is configured to receive a first portion of carbon dioxide stream 119 from power generation unit 150 and at least a portion of the electrical power generated by power generation unit 150. Ready-mix concrete production unit 170A uses a portion of the electrical power generated by power generation unit 150 to compress (e.g., with a compressor) and cool (e.g., with a heat exchanger) the first portion of carbon dioxide stream 119 to form high-pressure carbon dioxide stream 171. High-pressure carbon dioxide stream 171 is in a liquefied or supercritical state, allowing high-pressure carbon dioxide stream 171 to be easily transported to a building site where concrete is required. Ready-mix concrete production unit 170A is configured to discharge high-pressure carbon dioxide stream 171 and a first portion of concrete mixture 170" as ready-mix concrete stream 172. Ready-mix concrete stream 172 and high-pressure carbon dioxide stream 171 can be transported, for example, to a construction site where concrete is required. At the construction site, high-pressure carbon dioxide stream 171 can be depressurized and used to harden ready-mix concrete stream 172 to produce concrete. Hardening the ready-mix concrete stream 172 with carbon dioxide from high-pressure carbon dioxide stream 171 can mineralize at least a portion of the carbon dioxide.

[0023] Precast concrete production unit 170B is configured to receive the second portion of concrete mix 170" from ready mixed concrete production unit 170A and at least a portion of carbon dioxide stream 119 from power generation unit 150. In some embodiments, precast concrete production unit 170B is configured to receive at least a portion of the electrical power generated by power generation unit 150. Precast concrete production unit 170B is configured to use a portion of carbon dioxide stream 119 to cure the second portion of concrete mix 170" to produce precast concrete stream 174.

[0024] In some embodiments, precast concrete production unit 170B is configured to receive at least a portion of cement stream 170' and a portion of carbon stream 113 from carbon separation unit 130. Precast concrete production unit 170B can be configured to receive a portion of cement stream 170', a portion of carbon stream 113, and water (e.g., a portion of water stream 103 or a different water stream) to form a concrete mix. This may be the same as or similar to the concrete mix 170″ formed in ready mixed concrete production unit 170A. In some embodiments, aggregates (consisting of geological materials such as gravel, sand, and crushed stone) are also combined to form the concrete mix. Precast concrete production unit 170B can be configured to place the concrete mix within forms to produce precast concrete of a desired geometry. In some embodiments, the forms include rebar, which is steel reinforcement to provide structural strength and shape to the final precast concrete product. Precast concrete production unit 170B can use a portion of carbon dioxide stream 119 and a portion of the electricity generated by power generation unit 150 to harden the concrete mix and produce precast concrete stream 174.

[0025] In some embodiments, a portion of carbon dioxide stream 119 from power generation unit 150 is cooled and mixed with concrete mix 170″ in prefabricated forms. For example, a portion of carbon dioxide stream 119 is cooled to a maximum temperature of about 100° C. (degrees Celsius) or less. The carbon dioxide can accelerate the hardening of the concrete. At least a portion of the carbon dioxide can mineralize within the concrete as the concrete hardens. After concrete mix 170″ hardens in precast concrete production unit 170B to produce precast concrete streams 174, the remainder of the carbon dioxide can be channeled to ready mixed concrete production unit 170A. In some embodiments, ready mixed concrete production unit 170A and precast concrete production unit 170B are configured to operate in a series configuration. In some embodiments, ready mixed concrete production unit 170A and precast concrete production unit 170B are configured to operate in a parallel configuration.

[0026] In some embodiments, the system 100 includes a power distribution unit 160. The power distribution unit 160 can receive power from various power sources. For example, the power distribution unit 160 can be connected to a power grid to receive power. For example, the power distribution unit 160 can be connected to a renewable energy source (such as wind energy or solar energy) to receive power. For example, the power distribution unit 160 can be connected to a power generation unit 150 to receive power. For example, the power distribution unit 160 can be connected to a Rankine cycle to receive power (e.g., from a turbine in a Rankine cycle). The power distribution unit 160 can distribute the power to various users. For example, the power distribution unit 160 can be connected to deliver power to the electrolysis unit 140. For example, the power distribution unit 160 can be connected to deliver power to the pyrolysis chamber 110. For example, the power distribution unit 160 can be connected to a power grid to deliver power. For example, the power distribution unit 160 can be connected to a Rankine cycle (e.g., a pump in a Rankine cycle) to deliver power.

[0027] In some embodiments, at least a portion of the electrical power generated by power generation unit 150 is used by another component of system 100. For example, at least a portion of the electrical power generated by power generation unit 150 can be provided to electrolysis unit 140 to perform the electrolysis of water stream 103. For example, at least a portion of the electrical power generated by power generation unit 150 can be used to provide heat and / or power to pyrolysis chamber 110 to perform the pyrolysis of hydrocarbon feed stream 101. For example, at least a portion of the electrical power generated by power generation unit 150 can be used to pressurize carbon dioxide in ready-mix concrete production unit 170A to form high-pressure carbon dioxide stream 171. For example, at least a portion of the electrical power generated by power generation unit 150 can be used to produce a concrete mix in ready-mix concrete production unit 170A (e.g., for ready-mix concrete stream 172). For example, at least a portion of the electrical power generated by power generation unit 150 can be used to cure a concrete mix in ready-mix concrete production unit 170A to produce precast concrete stream 174. In some embodiments, at least a portion of the electrical power generated by power generation unit 150 is provided to other users. For example, at least a portion of the electrical power generated by power generation unit 150 can be used in other industrial processes. For example, at least a portion of the electrical power generated by power generation unit 150 can be delivered to the electrical grid where it can be stored and / or distributed to various off-site users.

[0028] FIG. 1B is a schematic diagram of an example pyrolysis chamber 110. In some embodiments, as shown in FIG. 1B, the pyrolysis chamber 110 includes a catalyst 110a. The catalyst 110a can include at least one of activated carbon, carbon black, cobalt, iron, copper, nickel, or other oxides / rare earth metals, such as lanthanum oxide or cerium oxide. The operating pressure within the pyrolysis chamber 110 can be substantially atmospheric pressure (approximately 1 atmosphere). The pyrolysis chamber 110 includes a heater 110b. When the pyrolysis chamber 110 is a plasma pyrolysis reactor, the heater 110b includes electrodes, and the pyrolysis chamber 110 is supplied with an inert gas along with the hydrocarbon feed stream 101. Electric power can be supplied to the electrodes of the heater 110b, and the inert gas serves as a working gas for generating plasma to pyrolyze the hydrocarbon feed stream. If the pyrolysis chamber 110 is a catalytic or non-catalytic reactor, the heater 110b provides indirect heat by a mechanism that generates radiant heat. For example, the heater 110b may be a gas-based burner or an electric heater that includes an electric resistor. If the heater 110b includes electrodes (plasma reactor) or an electric resistor (electric heater), electrical power is supplied to the heater 110b to generate heat within the pyrolysis chamber 110.

[0029] FIG. 1C is a schematic diagram of example components that may be included in gas separation unit 120. Gas separation unit 120 may include a gravity settling chamber, a cyclone, a baghouse filter, a microfilter, a pressure swing adsorption bed, a temperature swing adsorption bed, a dense membrane, or any combination thereof. As previously described, gas separation unit 120 separates gas stream 107 into exhaust gas stream 109 and a first hydrogen stream 111. First hydrogen stream 111 contains at least a majority of the hydrogen from gas stream 107, and exhaust gas stream 109 contains the remainder of gas stream 107. Thus, gas separation unit 120 is primarily used to extract hydrogen from gas stream 107. Pressure swing adsorption beds, temperature swing adsorption beds, dense membranes, or any combination thereof may be used to extract hydrogen from gas stream 107. In some cases, gas stream 107 may contain some solid particulates (e.g., solid carbon particulates entrapped in gas stream 107). In such cases, gravity settling chambers, cyclones, baghouse filters, microfilters, or any combination thereof, may be used to remove solids from gas stream 107. The components included in gas separation unit 120 are configured to operate within the expected operating range (operating pressure and temperature range) of gas stream 107 plus a design margin (e.g., ±5%, ±10%, ±15%, ±20%, ±25%, or ±30%). In some embodiments, gas stream 107 is cooled before entering gas separation unit 120.

[0030] 1C illustrates a gravity settling chamber, a cyclone, a baghouse filter, a pair of pressure swing adsorption beds, and a high-density membrane. In the gravity settling chamber and / or cyclone, the exit velocity of the gas stream 107 can be less than 300 cm / s (centimeters per second). For example, the exit velocity of the gas stream 107 from the gravity settling chamber can be about 275 cm / s, about 250 cm / s, about 225 cm / s, about 200 cm / s, about 175 cm / s, about 150 cm / s, about 125 cm / s, about 100 cm / s, about 90 cm / s, about 80 cm / s, about 70 cm / s, about 60 cm / s, about 50 cm / s, about 40 cm / s, about 30 cm / s, about 20 cm / s, about 10 cm / s, or about 5 cm / s. In some embodiments, the exit velocity of the gas stream 107 from the gravity settling chamber is desirably less than 30 cm / s. In some embodiments, the gravity settling chamber and / or cyclone are configured to remove solid particulates from the gas stream 107 having an average or maximum particle size ranging from about 10 microns to about 50 microns. The density of the solid particulates may also be a factor in separating the solid particulates from the gas stream 107. In a pressure swing adsorption bed, the extraction of hydrogen from the gas stream 107 depends on various factors, such as the pressure difference between the adsorption bed and the adsorbent. As shown in FIG. 1C, for a pressure swing adsorption bed, there are at least two vessels that swing over a range of pressures. In an adsorption process, a fluid (e.g., gas stream 107) flows through the adsorption bed in a first direction, and hydrogen is absorbed into the adsorption bed to produce an exhaust gas stream. In a desorption process, a fluid flows through the adsorption bed in a second direction, and hydrogen is desorbed from the adsorption bed to produce a first hydrogen stream 111.

[0031] 1D is a schematic diagram of example components that may be included in carbon separation unit 130. Carbon separation unit 130 may include a gravity settling chamber, a cyclone, a baghouse filter, a microfilter, a centrifuge, a wet dust collector, an electrostatic separator, an acid flux treatment device, or any combination thereof. As previously described, carbon separation unit 130 separates carbon from solids stream 105 to produce carbon stream 113. As such, carbon separation unit 130 is primarily used to extract carbon from solids stream 105. The components included in carbon separation unit 130 are configured to operate within the expected operating range (operating pressure and temperature range) of solids stream 105 plus a design margin (e.g., ±5%, ±10%, ±15%, ±20%, ±25%, or ±30%).

[0032] 1D illustrates a gravity settling chamber, a cyclone, a baghouse filter, and a centrifuge. In a gravity settling chamber and / or a cyclone, the exit velocity of the solids stream 105 can be less than 300 cm / s (centimeters per second). For example, the exit velocity of the solids stream 105 from the gravity settling chamber can be about 275 cm / s, about 250 cm / s, about 225 cm / s, about 200 cm / s, about 175 cm / s, about 150 cm / s, about 125 cm / s, about 100 cm / s, about 90 cm / s, about 80 cm / s, about 70 cm / s, about 60 cm / s, about 50 cm / s, about 40 cm / s, about 30 cm / s, about 20 cm / s, about 10 cm / s, or about 5 cm / s. In some embodiments, it is desirable for the exit velocity of the solids stream 105 from the gravity settling chamber to be less than 30 cm / s. In some embodiments, the gravity settling chamber and / or cyclone are configured to remove solid particles from the solids stream 105 having an average or maximum particle size ranging from about 10 microns to about 50 microns. Small particle sizes may be desirable for sale to external markets because smaller carbon particles have higher commercial value than larger carbon particles. In such cases, the larger carbon particles may be used, for example, for power generation. The density of the solid particles may also be a factor in the separation of the solid particles from the solids stream 105. In a centrifuge, the rotation speed may depend on the desired size of the carbon particles to be removed from the solids stream 105. For example, the rotation speed of the centrifuge may range from about 1,500 revolutions per minute (rpm) to about 50,000 rpm. In some cases, the rotation speed of the centrifuge may be greater than 50,000 rpm.

[0033] FIG. 1E is a schematic diagram of an example of an electrolysis unit 140. The electrolysis unit 140 shown in FIG. 1E is a polymer electrolyte membrane (PEM) electrolysis unit. However, different types of electrolysis units, such as an alkaline water electrolysis unit, a solid oxide electrolysis unit, or an anion exchange membrane (AEM) electrolysis unit, can be used instead or in addition. The PEM electrolysis unit 140 includes an anode 140a, a cathode 140b, and a proton exchange membrane 140c. The proton exchange membrane 140c is a solid polymer electrolyte membrane that electrically insulates the electrodes (140a, 140b) while conducting protons from the anode 140a to the cathode 140b. The half-reaction occurring at the anode 140a is also referred to as the oxygen evolution reaction (Equation 1). 2H2O → O2+4H + +4e - (Formula 1) The half-reaction that occurs on the side of the cathode 140b is also called the hydrogen evolution reaction. 4H + +4e - → 2H2 (Formula 2)

[0034] Water stream 103 is introduced into PEM electrolysis unit 140. PEM electrolysis unit 140 splits the water into hydrogen and oxygen. The hydrogen and oxygen produced are separated from each other. For example, the membrane may be hydrogen permeable, allowing hydrogen to pass through the membrane and be separated from the oxygen, while the oxygen remains on the other side of the membrane. Oxygen stream 115 exits PEM electrolysis unit 140 through the anode 140a side, and a second hydrogen stream 117 exits PEM electrolysis unit 140 through the cathode 140b side.

[0035] The open circuit voltage of the electrolysis unit 140 during operation can range from about 1.2 V (volts) to about 2.5 V. In some embodiments, the operating temperature of the PEM electrolysis unit 140 ranges from about 50° C. to about 80° C. In some embodiments, the operating pressure of the PEM electrolysis unit 140 is less than about 70 bar (about 7 MPa). In some embodiments, the current density of the power provided to the PEM electrolysis unit 140 is less than about 1 A / cm 2 (amperes per square centimeter) to approximately 6A / cm 2 The range is.

[0036] When the electrolysis unit 140 is an alkaline water electrolysis unit, the open circuit voltage of the electrolysis unit 140 during operation can range from about 1.2 V to about 3 V. In some embodiments, the operating temperature of the alkaline water electrolysis unit 140 ranges from about 70° C. to about 90° C. In some embodiments, the operating pressure of the alkaline water electrolysis unit 140 is less than about 70 bar (about 7 MPa). In some embodiments, the current density of the power provided to the alkaline water electrolysis unit 140 is less than about 0.2 A / cm 2 to about 6A / cm 2 The range is.

[0037] When electrolysis unit 140 is a solid oxide electrolysis unit, the open circuit voltage of electrolysis unit 140 during operation can range from about 1 V to about 1.5 V. In some embodiments, the operating temperature of solid oxide electrolysis unit 140 ranges from about 550°C to about 900°C, from about 700°C to about 850°C, or from about 750°C to about 800°C. In some embodiments, the operating pressure of solid oxide electrolysis unit 140 is less than about 30 bar (about 3 MPa). In some embodiments, the current density of the power provided to solid oxide electrolysis unit 140 is less than about 0.3 A / cm. 2 to about 6A / cm 2 The range is.

[0038] When electrolysis unit 140 is an AEM electrolysis unit, the open circuit voltage of electrolysis unit 140 during operation can range from about 1.2 V to about 2 V. In some embodiments, the operating temperature of AEM electrolysis unit 140 ranges from about 40° C. to about 80° C. In some embodiments, the operating pressure of AEM electrolysis unit 140 is less than about 70 bar (about 7 MPa). In some embodiments, the current density of the power provided to AEM electrolysis unit 140 is less than about 0.2 A / cm. 2 ~about 6A / cm 2 The range is.

[0039] FIG. 1F is a schematic diagram of an example of a direct carbon fuel cell 151. The exemplary direct carbon fuel cell 151 shown in FIG. 1F includes a solid oxide electrolyte 152, although different types of electrolytes, such as molten salts (e.g., hydroxide salts), molten carbonates, or molten tin anodes, can alternatively or additionally be used. Oxygen from oxygen stream 115 flows into the direct carbon fuel cell 151, and carbon from carbon stream 113 flows into the direct carbon fuel cell 151. The direct carbon fuel cell 151 combines the oxygen and carbon to produce carbon dioxide and electricity. Carbon dioxide stream 119 exits the direct carbon fuel cell 151. In some embodiments, the solid oxide electrolyte 152 is zirconium oxide (ZrO). In some embodiments, the solid oxide electrolyte 152 is doped with an oxide, such as yttrium oxide (YO) or scandium(III) oxide (ScO). The solid oxide electrolyte 152 combines carbon and oxygen to produce electricity and carbon dioxide at an operating temperature in the range of about 550°C to about 1,000°C, about 600°C to about 1,000°C, about 650°C to about 1,000°C, about 700°C to about 1,000°C, about 750°C to about 1,000°C, about 800°C to about 1,000°C, about 850°C to about 1,000°C, about 900°C to about 1,000°C, or about 950°C to about 1,000°C.

[0040] When the direct carbon fuel cell 151 includes a molten salt electrolyte (e.g., potassium hydroxide or sodium hydroxide), the direct carbon fuel cell 151 can be configured to combine carbon and oxygen to generate electricity and carbon dioxide at an operating temperature ranging from about 500°C to about 600°C. When the direct carbon fuel cell 151 includes a molten carbonate electrolyte (e.g., including lithium, sodium, and potassium), the direct carbon fuel cell 151 can be configured to combine carbon and oxygen to generate electricity and carbon dioxide at an operating temperature ranging from about 600°C to about 900°C. When the direct carbon fuel cell 151 includes a molten tin anode, the direct carbon fuel cell 151 can be configured to combine carbon and oxygen to generate electricity and carbon dioxide at an operating temperature of about 900°C.

[0041] FIG. 1G is a schematic diagram of an exemplary system 100G for the co-production of hydrogen, carbon, and power with waste heat recovery. System 100G is substantially the same as system 100 of FIG. 1A and can include substantially the same components. System 100G includes a first waste heat recovery heat exchanger 190G and a second waste heat recovery heat exchanger 190G′. The first waste heat recovery heat exchanger 190G is in fluid communication on a first side with at least a portion of gas stream 107 exiting pyrolysis chamber 110. The first waste heat recovery heat exchanger 190G is in fluid communication on a second side with a buffer fluid. The first waste heat recovery heat exchanger 190G is configured to transfer heat from some (or all) of gas stream 107 to the buffer fluid. Thus, gas stream 107 is cooled by the first waste heat recovery heat exchanger 190G before being processed in gas separation unit 120. The second heat recovery heat exchanger 190G' can be in fluid communication on a first side with at least a portion of the hydrocarbon feed stream 101 entering the pyrolysis chamber 110. The second heat recovery heat exchanger 190G' can be in fluid communication on a second side with a buffer fluid. The second heat recovery heat exchanger 190G' can be configured to transfer heat from the buffer fluid to some (or all) of the hydrocarbon feed stream 101 before it enters the pyrolysis chamber 110. In this manner, the first and second heat recovery heat exchangers 190G, 190G' cooperate to recover heat from the gas stream 107 and use the recovered heat to preheat some (or all) of the hydrocarbon feed stream 101 before it is pyrolyzed in the pyrolysis chamber 110. The buffer fluid is an intermediate fluid that transfers heat from the gas stream 107 to the hydrocarbon feed stream 101. The buffer fluid may be any suitable fluid capable of transferring heat from the gas stream 107 to the hydrocarbon feed stream 101. For example, the buffer fluid may be an aqueous fluid or an oil-based fluid (such as a hydrocarbon fluid). For example, the buffer fluid may include supercritical carbon dioxide.

[0042] FIG. 1H is a schematic diagram of an exemplary system 100H for simultaneous production of hydrogen, carbon, and power with waste heat recovery. The system 100H is substantially similar to the system 100 of FIG. 1A and can include substantially similar components. The system 100H includes a first waste heat recovery heat exchanger 190H and a second waste heat recovery heat exchanger 190H′. The first waste heat recovery heat exchanger 190H is in fluid communication on a first side with at least a portion of the carbon dioxide stream 119 exiting the power generation unit 150. The first waste heat recovery heat exchanger 190H is in fluid communication on a second side with a buffer fluid. The first waste heat recovery heat exchanger 190H is configured to transfer heat from some (or all) of the carbon dioxide stream 119 to the buffer fluid. The second waste heat recovery heat exchanger 190H′ can be in fluid communication on a first side with at least a portion of the hydrocarbon feed stream 101 entering the pyrolysis chamber 110. The second heat recovery heat exchanger 190H' can be in fluid communication with a buffer fluid on a second side. The second heat recovery heat exchanger 190H' can be configured to transfer heat from the buffer fluid to some (or all) of the hydrocarbon feed stream 101 before it enters the pyrolysis chamber 110. In this manner, the first and second heat recovery heat exchangers 190H, 190H' cooperate to recover heat from the gas stream 107 and use the recovered heat to preheat some (or all) of the hydrocarbon feed stream 101 before it is pyrolyzed in the pyrolysis chamber 110. The buffer fluid is an intermediate fluid that transfers heat from the gas stream 107 to the hydrocarbon feed stream 101. The buffer fluid can be any suitable fluid capable of transferring heat from the gas stream 107 to the hydrocarbon feed stream 101. For example, the buffer fluid may be an aqueous fluid or an oil-based fluid (such as a hydrocarbon fluid), or a supercritical fluid (such as supercritical carbon dioxide). Although Figures 1G and 1H show specific examples where waste heat may be recovered from specific areas within each system, waste heat recovery may be performed in any area where waste heat is generated.

[0043] FIG. 2 is a schematic diagram of an example Rankine cycle for generating electricity using heat. Cycle 200 includes a boiler 210, a turbine 220, a condenser 230, and a pump 240. Pump 240 circulates working fluid 202 through cycle 200. Working fluid 202 undergoes changes in temperature and pressure as it flows through cycle 200. The changes in temperature and pressure cause working fluid 202 to undergo phase changes as it flows through cycle 200. For clarity, various states of working fluid 202 (with changes in phase composition) are designated by a letter after 202 (e.g., 202a, 202b). The overall composition of working fluid 202 does not change as it flows through the cycle. However, individual phases (e.g., gas phase, liquid phase) may have varying compositions based on operating conditions, heat, and work (thermodynamics).

[0044] The working fluid 202 in a liquid state (202a) enters the boiler 210. The boiler 210 is configured to receive the liquid working fluid 202. The boiler 210 is configured to transfer heat to the working fluid 202 and generate a vaporized working fluid 202b. The vaporized working fluid 202b flows from the boiler 210 to the turbine 220. The turbine 220 is configured to receive the vaporized working fluid 202b. The turbine 220 is configured to generate power as the vaporized working fluid 202b flows into and expands through the turbine 220. The vaporized working fluid 202b exiting the turbine 220 has a reduced operating pressure compared to the vaporized working fluid 202b entering the turbine 220. The vaporized working fluid 202b flows from the turbine 220 to the condenser 230. The condenser 230 is configured to receive the vaporized working fluid 202b and condense it into a condensed working fluid 202a. The condensed working fluid 202a flows from the condenser 230 to a pump 240. The pump 240 is configured to circulate the condensed working fluid back to the boiler 210 to begin the cycle 200 again.

[0045] The heat that boiler 210 uses to vaporize working fluid 202 can be provided by a variety of sources. In some embodiments, boiler 210 receives heat from a buffer fluid (e.g., from first heat recovery heat exchanger 190G or 190H). For example, boiler 210 can be in fluid communication with the buffer fluid from first heat recovery heat exchanger 190G on a first side and with working fluid 202 on a second side. For example, boiler 210 can be in fluid communication with the buffer fluid of first heat recovery heat exchanger 190H on a first side and with working fluid 202 on a second side. In some embodiments, boiler 210 receives heat from the combustion of a fuel (e.g., from burning at least a portion of carbon stream 113 in the presence of oxygen from at least a portion of oxygen stream 115 in power generation unit 150).

[0046] In some embodiments, at least a portion of the electrical power generated by turbine 220 is used by components of system 100, 100G, or 100H. For example, at least a portion of the electrical power generated by turbine 220 can be provided to electrolysis unit 140 to perform electrolysis of water stream 103. For example, at least a portion of the electrical power generated by turbine 220 can provide heat to pyrolysis chamber 110 to be used to perform pyrolysis of hydrocarbon feed stream 101. In some embodiments, at least a portion of the electrical power generated by turbine 220 is provided to other users. For example, at least a portion of the electrical power generated by turbine 220 can be used in other industrial processes. For example, at least a portion of the electrical power generated by turbine 220 can be delivered to a power grid and stored therein and / or distributed to various off-site users. For example, at least a portion of the electrical power generated by turbine 220 can be provided to another process located on-site within the same facility as any of systems 100, 100G, or 100H.

[0047] 3 is a flow diagram of an exemplary method 300 for the simultaneous production of hydrogen, carbon, power, and sequesterable carbon dioxide for concrete production. Any of systems 100, 100G, and 100H can be used to implement method 300. A hydrocarbon feed stream (e.g., hydrocarbon feed stream 101) is introduced into a pyrolysis chamber (e.g., pyrolysis chamber 110). In block 302, hydrocarbon feed stream 101 is exposed to heat in the absence of oxygen (e.g., in pyrolysis chamber 110) to convert hydrocarbon feed stream 101 into a solids stream (e.g., solids stream 105) and a gas stream (e.g., gas stream 107). As previously described, solids stream 105 contains carbon, and gas stream 107 contains hydrogen. Gas stream 107 is then passed from pyrolysis chamber 110 to a gas separation unit (e.g., gas separation unit 120). In block 304, gas stream 107 is separated (e.g., in gas separation unit 120) into an exhaust gas stream (e.g., exhaust gas stream 109) and a first hydrogen stream (e.g., first hydrogen stream 111) containing at least a portion of the hydrogen from gas stream 107. Solids stream 105 is passed from pyrolysis chamber 110 to a carbon separation unit (e.g., carbon separation unit 130). In block 306, carbon is separated from solids stream 105 (e.g., in carbon separation unit 130) to produce a carbon stream (e.g., carbon stream 113). A water stream (e.g., water stream 103) is passed to an electrolysis unit (e.g., electrolysis unit 140). Electrical power is supplied to electrolysis unit 140. In block 308, water stream 103 is electrolyzed (e.g., by electrolysis unit 140 in response to electrical power) to produce an oxygen stream (e.g., oxygen stream 115) and a second hydrogen stream (e.g., second hydrogen stream 117). At least a portion of oxygen stream 115 is channeled from electrolysis unit 140 to a power generation unit (such as power generation unit 150). At least a portion of carbon stream 113 is channeled from carbon separation unit 130 to power generation unit 150. As previously mentioned, power generation unit 150 may include, for example, a direct carbon fuel cell 151. In block 310, oxygen from some (or all) of oxygen stream 115 and carbon from some of carbon stream 113 are combined (e.g., by direct carbon fuel cell 151) to produce electrical power and a carbon dioxide stream (such as carbon dioxide stream 119).At least a portion of the electrical power generated in block 310 is used to perform electrolysis of the water stream 103 (block 308). Thus, at least a portion of the electrical power used to perform the electrolysis in block 308 (e.g., in the electrolysis unit 140) is powered by at least a portion of the electrical power generated in block 310. In some embodiments, at least a portion of the electrical power generated in block 310 is used to perform the pyrolysis of the hydrocarbon feed stream 101 (block 302). In block 312, a second portion of the carbon stream 113, a cement stream (e.g., cement stream 170′), and water are combined (e.g., in ready-mix concrete production unit 170A) to form a concrete mix 170″. In some embodiments, the concrete mix 170″ also includes aggregate. In block 314, the second portion of the electrical power generated is used to pressurize a first portion of the carbon dioxide stream 119 to form a high-pressure carbon dioxide stream (e.g., high-pressure carbon dioxide stream 171). As previously described, the high-pressure carbon dioxide stream 171 is in a liquefied or supercritical state. In block 316, at least a portion of the high-pressure carbon dioxide stream 171 and a first portion of the concrete mix 170" are discharged (e.g., from ready-mix concrete production unit 170A) as a fresh concrete stream (e.g., fresh concrete stream 172). The fresh concrete stream 172 and the high-pressure carbon dioxide stream 171 can be transported to an off-site location where concrete is required, and the high-pressure carbon dioxide stream 171 can be depressurized and used to harden the fresh concrete, thereby mineralizing at least a portion of the carbon dioxide. In block 318, a second portion of the concrete mix 170" is hardened (e.g., in precast concrete production unit 170B) using the second portion of the carbon dioxide stream 119 and the third portion of the generated electricity (block 310) to produce a precast concrete stream (e.g., precast concrete stream 174). In some embodiments, after the second portion of concrete mix 170″ has cured to produce precast concrete stream 174 (block 318), the remainder of carbon dioxide stream 119 is flowed from precast concrete production unit 170B to ready mixed concrete production unit 170A to facilitate the formation of concrete mix 170″ (block 312).Excess carbon dioxide from the process can be used, for example, for other on-site or off-site industrial uses.

[0048] While this specification contains many details of specific implementations, these should not be construed as limiting the scope of the claims, but rather as descriptions of features specific to particular embodiments. Certain features described herein in the context of separate embodiments may also be implemented in combination in a single embodiment. Conversely, various features described in the context of a single embodiment may also be implemented in multiple embodiments separately or in any suitable subcombination. Furthermore, even if the features described above are described as acting in a particular combination and are initially claimed as such, one or more features from a claimed combination may, in some cases, be deleted from the combination, and the claimed combination may be directed to a subcombination or a variation of the subcombination.

[0049] As used in this disclosure, the terms "a," "an," or "the" are used to include one or more unless expressly stated otherwise. The term "or" is used to refer to a non-exclusive "or" unless otherwise specified. The phrase "at least one of A and B" is equivalent to "A or B, or A and B." Furthermore, it should be understood that words or terms used in this disclosure, unless otherwise defined, are for purposes of description only and not limitation. The use of section headings is intended to aid in the reading and comprehension of the document and should not be construed as limiting. Information associated with a section heading may be found within or outside of that particular section.

[0050] As used in this disclosure, the terms "about" or "approximately" allow for some variation in a value or range, for example, within 10%, within 5%, or within 1% of a stated value or boundary of a stated range.

[0051] As used in this disclosure, the term "substantially" refers to a majority or majority, such as at least about 50%, 50%, 60%, 70%, 80%, 90%, 95%, 96%, 97%, 98%, 99%, 99.5%, 99.9%, 99.99%, or at least about 99.999% or more.

[0052] Values ​​expressed in range format should be interpreted flexibly to include not only the numerical values ​​explicitly stated as the limits of the range, but also all individual numerical values ​​or subranges subsumed within that range, as if each numerical value and subrange were expressly stated. For example, a range of "0.1% to about 5%" or "0.1% to 5%" should be interpreted to include about 0.1% to about 5%, as well as individual values ​​(e.g., 1%, 2%, 3%, and 4%) and subranges within the indicated range (e.g., 0.1% to 0.5%, 1.1% to 2.2%, 3.3% to 4.4%). The phrase "X to Y" has the same meaning as "about X to about Y" unless otherwise specified. Similarly, the phrase "X, Y, or Z" has the same meaning as "about X, about Y, or about Z" unless otherwise specified.

[0053] Specific embodiments of the present subject matter have been described. As will be apparent to those skilled in the art, other implementations, modifications, and permutations of the described embodiments are within the scope of the following claims. Although the figures or claims may depict operations in a particular order, this should not be understood as requiring such operations to be performed in the particular order or hierarchy depicted to achieve desired results, or as requiring that all depicted operations be performed (some operations may be considered optional). In certain situations, multitasking or parallel processing (or a combination of multitasking and parallel processing) may be advantageous and may be performed where deemed appropriate.

[0054] Furthermore, it should be understood that the separation or integration of various system modules and components in the above embodiments should not be understood to require such separation or integration in all embodiments, and that the described components and systems may generally be integrated together or packaged into multiple products.

[0055] Therefore, the foregoing exemplary implementations do not define or constrain this disclosure, and other changes, substitutions, and alterations are also possible without departing from the spirit and scope of this disclosure.

Claims

1. exposing a hydrocarbon feed stream comprising hydrocarbons to heat in the absence of oxygen to convert the hydrocarbon feed stream into a solids stream comprising carbon and a gas stream comprising hydrogen; separating the gas stream into an exhaust gas stream and a first hydrogen stream comprising at least a portion of the hydrogen from the gas stream; separating the carbon from the solids stream to produce a carbon stream; performing electrolysis on a water stream comprising water to produce an oxygen stream comprising oxygen and a second hydrogen stream comprising hydrogen; reacting at least a portion of the oxygen from the oxygen stream with a first portion of the carbon stream to generate electricity and a carbon dioxide stream comprising carbon dioxide, wherein the first portion of the generated electricity is used to perform electrolysis on the water stream; mixing a second portion of the carbon stream with a cement stream containing cement and water to form a concrete mix; compressing a first portion of the carbon dioxide stream using a second portion of the generated electrical power to form a high-pressure carbon dioxide stream in a liquefied or supercritical state; Discharging the high-pressure carbon dioxide stream and discharging a first portion of the concrete mix as a ready-mix concrete stream; curing a second portion of the concrete mix using a second portion of the carbon dioxide stream to produce a precast concrete stream; and A method comprising:

2. 10. The method of claim 1, wherein the hydrocarbon feed stream comprises one or more C1 to C22 alkanes, one or more C1 to C22 alkenes, or any combination thereof.

3. The method of claim 2 wherein the hydrocarbon feed stream comprises hydrogen.

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

5. The method of claim 4 , including transferring heat from the gas stream to a buffer fluid by a first waste heat recovery heat exchanger.

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

7. 10. The method of claim 1, further comprising flowing the remainder of the carbon dioxide stream into a ready mixed concrete production unit after the second portion of the concrete mix has hardened to produce the precast concrete stream.

8. The method of claim 4 , comprising transferring heat from the carbon dioxide stream to a buffer fluid by a first waste heat recovery heat exchanger.

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

10. 5. The method of claim 4, comprising sequestering the carbon dioxide stream produced by the direct carbon fuel cell in a subterranean formation such that the carbon dioxide stream is not released into the atmosphere.

11. a hydrocarbon feed stream comprising hydrocarbons; a pyrolysis chamber configured to receive the hydrocarbon feed stream and expose the hydrocarbon feed stream to heat in the absence of oxygen to convert the hydrocarbon feed stream into a solids stream comprising carbon and a gas stream comprising hydrogen; a gas separation unit configured to receive the gas stream from the pyrolysis chamber and separate the hydrogen from the gas stream to produce an exhaust gas stream and a first hydrogen stream comprising at least a portion of the hydrogen from the gas stream; a carbon separation unit configured to receive the solids stream from the pyrolysis chamber and separate the carbon from the solids stream to produce a carbon stream; a water stream containing water; an electrolysis unit configured to receive the water stream and electrical power, and configured to perform electrolysis on the water stream using the electrical power to produce an oxygen stream comprising oxygen and a second hydrogen stream comprising hydrogen; a power generation unit configured to receive at least a portion of the oxygen stream from the electrolysis unit and a first portion of the carbon stream from the carbon separation unit, the power generation unit including a direct carbon fuel cell configured to react the oxygen from the portion of the oxygen stream with carbon from the first portion of the carbon stream to produce electricity and a carbon dioxide stream comprising carbon dioxide, the first portion of the electricity generated by the power generation unit being supplied to the electrolysis unit to perform electrolysis on the water stream; a cement flow containing cement; a ready-mix concrete production unit configured to receive the cement stream and a second portion of the carbon stream and to mix the cement stream, the second portion of the carbon stream, and water to form a concrete mix, the ready-mix concrete production unit configured to receive a first portion of the carbon dioxide stream from the power generation unit and a second portion of the electricity generated by the power generation unit, and to pressurize the first portion of the carbon dioxide stream using the second portion of the electricity generated by the power generation unit to form a high-pressure carbon dioxide stream in a liquefied or supercritical state, and to discharge the high-pressure carbon dioxide stream and discharge the first portion of the concrete mix as a ready-mix concrete stream; a precast concrete production unit configured to receive a second portion of the concrete mix from the ready-mix concrete production unit and a second portion of the carbon dioxide stream from the power generation unit, the precast concrete production unit configured to use the second portion of the carbon dioxide stream to harden the second portion of the concrete mix to produce a precast concrete stream; A system comprising:

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

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

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

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

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

17. 12. The system of claim 11, wherein the precast concrete production unit is configured to flow the remainder of the carbon dioxide stream into the ready mixed concrete production unit after the second portion of the concrete mix has hardened to produce the precast concrete stream.

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

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

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

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