Integrated energy system for direct carbon dioxide capture from emissions sources for methanol production.

Abstract

This specification describes techniques that may be implemented in an integrated energy system (IES). An IES may include a power plant, an emission source, and a chemical processing plant. An IES may include one or more subplants configured to receive carbon dioxide from an emission source, convert a first part of the carbon dioxide into carbon monoxide, receive sodium hydroxide, combine the carbon monoxide and sodium hydroxide to produce hydrogen gas, and use a reaction chamber to combine the second part of the carbon dioxide, carbon monoxide, and hydrogen to produce methanol.

Description

[Technical Field]

[0001] Cross-reference of related applications This application claims the benefit of U.S. Patent Application No. 18 / 737,623, filed on 7 June 2024, entitled “Integrated Energy Systems For The Direct Capture Of Carbon Dioxide From Emissions Sources For Methanol Production,” which claims priority to U.S. Provisional Patent Application No. 63 / 507,057, filed on 8 June 2023, entitled “NUCLEAR REACTOR INTEGRATED ENERGY SYSTEMS FOR THE DIRECT CAPTURE OF CARBON DIOXIDE FROM EMISSIONS SOURCES FOR METHANOL PRODUCTION,” which is incorporated herein by reference in its entirety.

[0002] This technology applies to reactor integrated energy systems (IES) for energy generation and green industrial applications such as carbon dioxide capture and green methanol production, as well as related devices and methods. [Background technology]

[0003] Cumulative carbon dioxide (CO2) emissions are a major driver of climate change. The majority of CO2 emissions are generated from the combustion of fossil fuels for electricity, for use in the production of heat and steam, and for transportation. The seven largest CO2-emitting industries in the world are (1) power plants (coal, natural gas, and oil combustion), (2) oil refineries, (3) ammonia production plants, (4) chemical manufacturing and production plants, (5) cement production plants, (6) steel manufacturing plants, and (7) transportation. President Biden has set a goal for the United States to be fully carbon-free by 2035. The proposed new EPA rules are expected to accelerate progress in carbon capture and help provide utility options for reducing carbon dioxide (CO2) emissions, such as installing new carbon capture systems or switching to cleaner fuels. However, despite the new rules, tax credits, and the trend of increasing renewable energy adoption, electric utilities are reluctant to adopt new technologies and methods due to their high cost. Thus, fossil fuels will continue to play a significant role in global energy supply and industrial processes.

[0004] To address the challenges of climate change, there is a need to develop ways to integrate carbon capture into current industrial operations. However, carbon sequestration from atmospheric carbon dioxide (CO2) and industrial emissions presents significant challenges. For example, direct air capture (DAC) and carbon capture, use, and storage (CCUS) facilities are capital-intensive to deploy and energy-intensive to operate. In either scenario, the energy used to capture carbon dioxide (CO2) determines whether and to what extent the system is net-negative for carbon, and can also be a critical determinant of the cost per ton of captured carbon dioxide (CO2). Furthermore, the choice of location must be based on the energy sources necessary to operate the DAC or CCUS plant. Thus, the success of these technologies from an economic and regulatory standpoint depends on the availability of low-carbon energy sources in the region. Therefore, there is a need to address the challenges of climate change by developing ways to reduce or eliminate carbon dioxide (CO2) emissions in power production and by integrating carbon capture technologies into industrial processes. [Brief explanation of the drawing]

[0005] Detailed explanations are provided with reference to the attached figures. In each figure, the number at the left of the reference number identifies the figure in which that reference number first appears. The use of the same reference number in different figures indicates similar or identical items or features.

[0006] [Figure 1] This is a schematic diagram of an integrated energy system for producing purified water and capturing carbon dioxide (CO2), according to at least some embodiments. [Figure 2] A schematic diagram of an integrated energy system for capturing and converting carbon dioxide (CO2) from emission sources is depicted, according to at least some embodiments. [Figure 3] This is a block diagram illustrating the use of a solid oxide electrolytic cell (SOEC) in at least some embodiments. [Figure 4]A block diagram illustrating a chlor-alkali membrane process in at least several embodiments is depicted. [Figure 5] A block diagram illustrating a hydrogen (H2) and sodium oxalate (Na2C2O4) plant according to at least some embodiments is shown. [Figure 6] This is a block diagram illustrating an example of a methanol production plant according to at least several embodiments. [Figure 7] This is a schematic diagram of a nuclear power plant system including multiple reactors according to an embodiment of this technology. [Figure 8] These are partial schematic and partial cross-sectional views of a reactor system configured according to an embodiment of this technology. [Figure 9] These are partial schematic and partial cross-sectional views of a reactor system configured according to an additional embodiment of this technology. [Figure 10] This document illustrates an example of a process for carbon capture and methanol (CH3OH) production using an additional embodiment of this technology. [Modes for carrying out the invention]

[0007] This technology provides devices and methods for directly removing carbon dioxide (CO2) from emission sources such as natural gas or coal-fired power plants, chemical product production plants, refineries, ore processing plants, steel processing plants, and / or other generators of greenhouse gases. In embodiments, this disclosure covers techniques, as well as related devices and methods, that may be implemented in connection with integrated energy systems (IESs), such as for use in green industrial processes that produce little to no carbon emissions, for capturing carbon from emission sources, and for resource generation. The IES of this technology includes a power plant (e.g., a primary power plant) integrated with one or more industrial processes and resource generation plants that can provide electricity with little to no carbon emissions, capture carbon dioxide (CO2) directly from emission sources, and generate resources from the captured carbon dioxide (CO2).

[0008] Examples of industrial processes according to embodiments of this technology include water purification, chemical manufacturing and production, natural gas or coal-fired power plants, petroleum refining and oil production, recycling and gasification of bulk plastic waste, cement production, ore processing plants, steel and primary metal manufacturing, transportation, food processing, pharmaceutical production, pulp and paper, material manufacturing, and / or other industrial plants. Such IESs may be capable of providing electricity and steam, or a combination thereof, to industrial processes for resource generation, such as carbon capture and chemical product generation, from power plants. The IESs of this disclosure can also help industries meet EPA and other national and global regulations to reduce carbon dioxide (CO2) emissions. In embodiments, the IESs may be modular and therefore can be retrofitted to existing industrial processes for carbon capture and resource generation.

[0009] Driven by the pursuit of cleaner and more efficient forms of electricity production, nuclear power will become increasingly important in the coming years. During operation, nuclear power plants use the nuclear fission process to generate heat, which is then used to produce steam that rotates a turbine, generating electricity. This process can lead to electricity production that reduces the need for coal and natural gas to produce power. Because nuclear power plants provide reliable baseload power without emitting greenhouse gases such as carbon dioxide (CO2) during operation, they are attractive to countries seeking to reduce carbon emissions and enhance energy security. Given the advantages of nuclear energy for providing electricity, this disclosure presents novel ways of using nuclear power in integrated energy systems for carbon capture and “green” resource generation, such as the production of “green” chemical products.

[0010] In some embodiments, the IES includes a power plant system having multiple small modular reactors (SMRs) specifically configured to work together to support one or more industrial processes. SMRs are smaller in size (e.g., dimensions) and power compared to large conventional reactors. Furthermore, they are modular in that some or all of their systems and components can be assembled in a factory and transported as units to the installation site. In some aspects of the art, multiple SMRs in an integrated energy system can flexibly and dynamically provide electricity, steam, or a combination of both to industrial processes due to the modularity and flexibility of the SMRs. That is, the configuration of the SMRs can be switched during operation to provide various levels of steam and electricity output depending on the operating state and / or requirements of the industrial processes.

[0011] The power plants of this disclosure may be permanent or temporary installations constructed at or near (e.g., approximately 1 km from) an industrial process facility, or they may be mobile or partially mobile systems that are moved to and assembled at or near an industrial process facility. More generally, a power plant may be local to the industrial process / operation it supports (e.g., located there or near it). For example, a power plant may be located within 0.4 km (0.25 miles), 0.8 km (0.5 miles), 3.22 km (2 miles), 4.82 km (3 miles), or 8.1 km (5 miles) of the industrial process / operation it supports. In embodiments, the power plant is configured to supply a portion of the electricity to the power grid.

[0012] In some embodiments, the disclosure includes systems and methods that can address many of the problems associated with conventional carbon dioxide (CO2) capture and storage solutions, such as economic viability. In embodiments, the IES of the disclosure can capture carbon dioxide (CO2) from industrial emission sources and utilize the captured carbon dioxide (CO2) to produce one or more resources and / or products. In embodiments, the resources and / or products produced in the IES can be sold directly to industry. In embodiments, the resources and / or products in the IES can be further utilized to produce other resources and / or products that can be used in the IES or sold to industry. By utilizing captured carbon dioxide (CO2) to produce marketable resources and / or products, the cost per ton of captured carbon dioxide (CO2) is reduced.

[0013] In some embodiments, an IES may capture carbon dioxide (CO2) from an emission source and process the captured carbon dioxide (CO2) in one or more resource production plants to produce marketable resources and / or products. For example, an IES may be operably connected to a methanol production plant where the captured carbon dioxide (CO2) is converted to methanol (CH3OH). Methanol (CH3OH), also known as methyl alcohol, is a versatile chemical widely used in industry and prevalent in everyday life. It is a base material in the production of acetic acid and formaldehyde, and its use is increasing in the production of ethylene and propylene. Methanol (CH3OH) is one of the most productive intermediate materials for producing other chemicals and materials. In the chemical industry, methanol (CH3OH) primarily serves as a raw material in the production of formaldehyde, olefins, acetic acid, MTBE, DME, and biodiesel. Therefore, renewable methanol (CH3OH) is a prerequisite for greening a wide range of chemical products, including polymer fibers for the textile industry, packaging plastics, glues, adsorbents / diapers, paints, adhesives, solvents, and many others. In addition to its use in the chemical, construction, and plastics industries, methanol (CH3OH) also serves as a fuel or fuel additive.

[0014] Conventional methods for producing methanol (CH3OH) involve catalytic processes using fossil raw materials such as natural gas, coal, or synthesis gas. Currently, most methanol (CH3OH) is produced from the catalytic conversion of carbon dioxide (CO2) and hydrogen (H2). The main method for producing carbon dioxide (CO2) and hydrogen (H2) for methanol (CH3OH) production is by steam-methane reforming of natural gas. However, the steam reforming process results in significant carbon dioxide (CO2) emissions into the atmosphere. The catalytic hydrogenation of carbon dioxide (CO2) for methanol (CH3OH) production also results in the formation of water as a by-product, which leads to the dynamic inhibition and accelerated inactivation of the Cu / ZnO catalyst. To counteract the formation of water and prevent the inactivation of the Cu / ZnO catalyst, carbon monoxide (CO) is required in the reaction chamber to remove water via the water-gas shift (WGS) reaction.

[0015] In embodiments of the present disclosure, the IES can produce carbon dioxide (CO2), hydrogen (H2), and carbon monoxide (CO) for the production of methanol (CH3OH). In an embodiment, carbon dioxide (CO2) can be captured from an emission source and separated from oxides, particulates, and other contaminants in a separator such as a scrubber, and carbon monoxide (CO) gas for the water-gas shift (WGS) reaction can be generated from the captured carbon dioxide (CO2) in a solid oxide electrolysis cell (SOEC), and hydrogen (H2) can be formed from by-products of industrial processes.

[0016] In some embodiments, the IES is operably connected to a water source such as an ocean. In an embodiment, water from the water source is supplied to a water purification plant such as a reverse osmosis (RO) desalination plant configured to produce clean water. As climate change progresses, water scarcity will become an increasing threat to countries and individuals around the world. Approximately 30% of the world's population lives in countries experiencing water stress, and 9% lives in countries experiencing severe water stress. Desalination has been successfully implemented in many regions, reducing the adverse effects of water scarcity by providing clean and high-quality water to the residents of those regions. However, desalination is a resource- and energy-intensive process involving reverse osmosis (RO), the most commonly used desalination process, which requires 3.44 - 22.36 kWh / m 3 is required. Worldwide, RO accounts for approximately 69% of the installed desalination capacity, or approximately 69 million m 3 / day, which corresponds to approximately 33 billion kg of carbon dioxide (CO2) emissions per year for clean RO water. Therefore, there is a need to develop an integrated energy system that produces little or no carbon emissions in order to reduce the carbon footprint of clean water production.

[0017] The desalination of seawater also produces large amounts of brine as a byproduct. Brine is a high-concentration salt and aqueous solution, mainly sodium chloride (NaCl) in the range of approximately 5% to approximately 26%. Since brine is denser than seawater, it sinks to the seabed and can damage the ecosystem if released directly. The desalination of seawater by RO produces approximately 1.4 liters of brine per liter of clean water. In other words, in order for RO to produce 69 million m 3 / day of fresh water on a global scale, the presence of 97 million m 3 / day of brine that requires proper environmental disposal is inevitable. Therefore, there is a need to develop an integrated energy system that produces little or no carbon emissions and can address the current brine formation burden in seawater desalination.

[0018] In embodiments, the disclosure includes methods and devices that can address many of the problems associated with conventional clean water production solutions, such as the production of clean water with little to no carbon emissions. In embodiments, the IES of the disclosure can utilize by-products of clean water production, such as brine from an RO desalination plant, in resource production. In embodiments, the IES can convert brine, which has been converted into a useful and / or marketable product, into low-salinity saline water that can be recycled to a water treatment facility such as a desalination plant. In embodiments, the resources and / or by-products produced in the IES can be sold directly to industry. In embodiments, the by-products and / or resources can be further processed to produce other resources that can be used within the IES or sold to industry, thereby reducing the cost per ton of clean water produced.

[0019] Aspects of this disclosure include processing brine from water treatment plants, such as reverse osmosis (RO) desalination plants, and converting it into useful industrial chemicals. In some embodiments, the brine is supplied to a chlor-alkali membrane process. A chlor-alkali process is an electrolytic process demonstrated to process brine to produce a sodium hydroxide (NaOH) solution, chlorine (Cl2) gas, and hydrogen (H2) gas from a sodium chloride (NaCl) brine solution and purified water. The purified water used in the chlor-alkali process can be supplied directly from an RO plant. The generated chlorine (Cl2) gas and hydrogen (H2) gas can be removed as products or used for further resource generation, such as forming hydrogen chloride (HCl) gas by combining chlorine (Cl2) gas and hydrogen (H2) gas to convert it to hydrochloric acid (HCl). The generated sodium hydroxide (NaOH) solution can be removed as a product or used for further resource generation, such as the production of hydrogen (H2).

[0020] In this embodiment, a sodium hydroxide (NaOH) solution from a chlor-alkali film process can be supplied to an oven, such as a thermal vacuum dehydration chamber, to form solid sodium hydroxide (NaOH). The solid sodium hydroxide (NaOH) can then be supplied to a reaction chamber and introduced under pressure to carbon monoxide (CO) from, for example, a solid oxide electrolytic cell (SOEC), causing the reaction to produce sodium formate (HCOONa). The sodium formate (HCOONa) can then undergo thermal decomposition to produce hydrogen (H2) and sodium oxalate (Na2C2O4). The sodium oxalate (Na2C2O4) can be sold to industry or used for further resource generation, for example, as a component for water treatment, food additives, and the production of other chemicals. The hydrogen (H2) can be supplied to the reaction chamber along with carbon dioxide (CO2) and carbon monoxide (CO) from, for example, an SOEC, for the formation of methanol (CH3OH). By-products from the SOEC, such as oxygen, can be sold to industry or used for further resource generation.

[0021] The current industrial process for methanol (CH3OH) production is the steam-methane reforming process. This process is energy-intensive and generates significant amounts of carbon dioxide (CO2) emissions. Integrating the above steps for the capture and utilization of industrial carbon dioxide (CO2) for the production of methanol (CH3OH) and other marketable resources using carbon-free electricity offers countless benefits to recent state-of-the-art technologies. In embodiments, the IES of this disclosure takes electricity, saline water, and carbon dioxide (CO2) from an emission source as inputs and converts these inputs into useful and marketable products such as purified water, methanol (CH3OH), hydrogen chloride (HCl) gas, and hydrochloric acid (HCl), sodium oxalate (A2C2O4), oxygen (O2), sodium hydroxide (NaOH), chlorine (Cl2), hydrogen (H2), and sodium formate (HCOONa) via hydrogen (H2) and chlorine (Cl2) gases. In embodiments, the IES generates minimal emissions, waste, and by-products. In this embodiment, the IES generates no carbon emissions and results in net negative carbon emissions through the capture and use of carbon dioxide (CO2) from emission sources.

[0022] Certain details are described below and in Figures 1-10 to provide a complete understanding of the various embodiments of the Art. In other cases, well-known structures, materials, operations, and / or systems related to nuclear reactors, power plant systems, integrated energy systems, chemical production plants, industrial process plants, electrolysis systems, hydrogen and oxygen production plants, direct air capture (DAC) plants, refineries, and similar structures, materials, operations, and / or systems are often not described or described in detail below to avoid unnecessarily obscuring the description of the various embodiments of the Art. However, those skilled in the art will recognize that the Art can be practiced without one or more of the details described herein and / or with other structures, methods, components, etc. The terms used below should be interpreted in their broadest and most reasonable form, even though they are used in conjunction with the detailed description of certain examples of embodiments of the Art.

[0023] The accompanying figures illustrate embodiments of the present technology and are not intended to limit its scope unless expressly indicated. The sizes of the various elements depicted are not necessarily drawn to a constant scale, and these elements may be enlarged to improve readability. Details of components may be abstracted in the figures to exclude details such as the arrangement of components and certain precise connections between such components, where such details are not necessary for a complete understanding of how the present technology is manufactured and used. Many of the details, dimensions, angles, and other features shown in the figures are merely illustrative examples of particular embodiments of the present disclosure. Other embodiments may have other details, dimensions, angles, and features without departing from the present technology. In addition, those skilled in the art will understand that further embodiments of the present technology may be practiced without some of the details described below.

[0024] Each of the references cited herein is incorporated herein in its entirety by reference. However, in the event that any material incorporated herein by reference conflicts with the disclosure, the disclosure shall prevail. The headings provided herein are for convenience only and should not be construed as limiting the subject matter disclosed.

[0025] Figure 1 is a schematic diagram of the integrated energy system (IES) 100 of the present disclosure. In an embodiment, the IES 100 receives electricity from a power plant 102, saline water from a water source 104, and carbon dioxide (CO2) from an emission source 106 as inputs. In an embodiment, the IES 100 includes one or more resource generation plants 108 configured to convert the inputs into useful and marketable products.

[0026] In the embodiment, the IES100 is operably connected to a power plant 102, which is configured to supply power to the IES100. In the embodiment, the power plant 102 may include the power plant system 750 of Figure 7, according to an additional embodiment of the present technology. The power plant 102 may include one or more light water reactors (LWRs), one or more small modular reactors (SMRs), and a nuclear module (NPM) including any reactor 700 of Figure 7, reactor system 800 of Figure 8, and reactor system 900 of Figure 9.

[0027] In the embodiment, IES100 is operably connected to a water source 104. In the embodiment, the water source 104 includes natural bodies of water such as oceans, seas, or lakes, storage tanks, industrial processes, and water treatment facilities. In the embodiment, the water source 104 provides IES100 with saline water such as seawater, brackish water, and brine. In the embodiment, the saline water may have a dissolved salt concentration of 0.05% to 50%. For example, seawater from the world's oceans has a salt concentration of about 3.5%, and salt lakes and seas around the world have a salt concentration of 0.59% to 50%. In the embodiment, the saline water contains salts such as sodium chloride (NaCl).

[0028] In the embodiment, the IES100 is operably connected to an emission source 106 and is configured to capture carbon in the form of carbon dioxide (CO2) from the emission source 106. In the embodiment, the emission source 106 may include a natural gas or coal-fired power plant, a chemical product production plant, an oil refinery, an ore processing plant, a steel processing plant, and / or other industrial plant.

[0029] In embodiments, IES100 produces a primary product 110 in one or more resource generation plants 108. In embodiments, the primary product 110 may include purified water, methanol (CH3OH), hydrogen chloride (HCl) gas, hydrochloric acid (HCl), sodium oxalate (Na2C2O4), and oxygen (O2). In some cases, the primary product 110 may be stored and / or sold to consumers. In embodiments, any one portion of the primary product 110 may be recycled within IES100. In embodiments, IES100 produces an intermediate product 112 in one or more resource generation plants 108. In embodiments, the intermediate product 112 may include sodium hydroxide (NaOH) solution, sodium hydroxide (NaOH) solid, chlorine (Cl2), hydrogen (H2), and sodium formate (HCOONa). In embodiments, the intermediate product 112 may be recycled within IES100. In some cases, a portion of any one of the intermediate products 112 may be stored and / or sold to consumers. In embodiments, IES 100 may produce waste 114 containing low-concentration brine (e.g., 3.5% sodium chloride (NaCl)) and contaminants separated from carbon dioxide (CO2) from emission source 106, such as particulate matter, sulfur oxides, and other gases. In embodiments, waste 114 may be recycled within IES 100. In some cases, all or a portion of any one of the waste 114 may be stored, sold to consumers, further processed for safe disposal, and / or safely released into the environment. In embodiments, IES 100 produces minimal emissions, waste, and by-products. In embodiments, IES 100 generates no carbon emissions and results in net negative carbon emissions through the capture and use of carbon dioxide (CO2) from emission source 106.

[0030] In embodiments, the power plant 102 may be a permanent or temporary facility constructed at or near (e.g., approximately 1 km from) the water source 104, the emission source 106, and / or the resource generation plant 108, or it may be a mobile or partially mobile system that is moved to and assembled at or near the water source 104, the emission source 106, and / or the resource generation plant 108. More generally, the power plant 102 may be local to the industrial process / operation it supports (e.g., located there or nearby). For example, the power plant may be located within 0.4 km (0.25 miles), 0.8 km (0.5 miles), 3.22 km (2 miles), 4.82 km (3 miles), or 8.1 km (5 miles) of the industrial process / operation it supports. In embodiments, the power plant 102 is configured to supply a portion of the electricity to the power grid.

[0031] Figure 2 is a schematic diagram of an integrated energy system (IES) 200 of the present disclosure. In embodiments, the IES 200 is operably connected to a power plant 202. In embodiments, the power plant 202 is configured to supply power to the IES 200. In embodiments, the power plant 202 may include a power plant system 750 of Figure 7, according to additional embodiments of the present technology. The power plant 202 may include one or more light water reactors (LWRs), one or more small modular reactors (SMRs), and a nuclear module (NPM) including any reactor 700 of Figure 7, reactor system 800 of Figure 8, and reactor system 900 of Figure 9.

[0032] In some embodiments, the IES200 is operably connected to one or more emission sources 204 and is configured to capture carbon in the form of carbon dioxide (CO2) from the emission sources 204 for use in resource generation. In embodiments, the emission sources 204 may include natural gas or coal-fired power plants, chemical product production plants, refineries, ore processing plants, steel processing plants, and / or other industrial plants.

[0033] In the embodiment, carbon dioxide (CO2) emissions from emission source 204 may be supplied to one or more scrubbers 206. One or more scrubbers 206 may be configured to separate carbon dioxide (CO2) from particulate matter, sulfur oxides, other gases, and pollutants emitted by emission source 204. One or more scrubbers 206 may include wet or dry scrubbers for removing sulfur oxides. One or more scrubbers 206 may include filters and / or fly ash removers for removing particulate matter. In the embodiment, the scrubbers 206 are configured to receive power from a power plant 202.

[0034] In embodiments, IES200 may include a carbon dioxide (CO2) conversion plant 208 configured to convert carbon dioxide (CO2) to carbon monoxide (CO) and oxygen (O2). In embodiments, the carbon dioxide (CO2) conversion plant 208 may include the carbon dioxide (CO2) conversion plant 300 shown in Figure 3. In embodiments, carbon dioxide (CO2) from a scrubber 206 may be supplied to the carbon dioxide (CO2) conversion plant 208. In embodiments, the carbon dioxide (CO2) conversion plant 208 may include one or more solid oxide electrolytic cells (SOECs) for converting carbon dioxide (CO2) to carbon monoxide (CO) and oxygen (O2). In embodiments, the carbon dioxide (CO2) conversion plant 208 may include one or more additional separation processes for separating carbon dioxide (CO2) from carbon monoxide (CO), such as pressure swing adsorption (PSA), membranes, and / or cryogenic separation. In embodiments, the carbon dioxide (CO2) conversion plant 208 may include one or more separation processes, such as pressure swing adsorption (PSA), membrane, and / or cryogenic separation, for separating carbon dioxide (CO2) from oxygen (O2). In embodiments, the carbon dioxide (CO2) in the carbon dioxide (CO2) conversion plant 208 may be recycled to increase conversion efficiency. The oxygen (O2) produced in the carbon dioxide (CO2) conversion plant 208 may be stored, further purified, used in downstream processes, and / or sold. The carbon dioxide (CO2) and carbon monoxide (CO) from the carbon dioxide (CO2) conversion plant 208 may be supplied to downstream processes or recycled within IES200 for resource generation. In embodiments, the carbon dioxide (CO2) conversion plant 208 is configured to receive electricity and / or thermal energy from the power plant 202.

[0035] In embodiments, IES200 includes a water treatment plant 210. The water treatment plant 210 may include one or more water treatment processes such as reverse osmosis (RO), distillation, and filtration. The water treatment plant 210 may receive water from a water source. In embodiments, the water source includes natural bodies of water such as oceans, seas, or lakes, storage tanks, industrial processes, and separate water treatment facilities. In embodiments, the water source provides the water treatment plant 210 with saline water such as seawater, brackish water, and brine. In embodiments, the saline water may have a dissolved salt concentration of 0.05% to 50%. For example, seawater from the world's oceans has a salt concentration of about 3.5%, and salt lakes and seas around the world have a salt concentration of 0.59% to 50%. In embodiments, the saline water contains salts such as sodium chloride (NaCl). In embodiments, the water treatment plant 210 is configured to receive electricity from a power plant 202.

[0036] In this embodiment, the water treatment plant 210 produces purified water and brine. In the illustrated example, saline water, such as seawater with a salinity of 3.5% sodium chloride (NaCl), is supplied to the water treatment plant 210. The water treatment plant 210 converts the saline water into purified water (e.g., with a sodium chloride (NaCl) concentration of less than 0.05%) and brine (e.g., with a sodium chloride (NaCl) concentration of 7.5%).

[0037] In the embodiment, brine (e.g., 7.5% sodium chloride (NaCl) concentration) from the water treatment plant 210 is supplied to a chlor-alkali membrane process 212, such as the chlor-alkali membrane process 400 shown in Figure 4. In the embodiment, a portion of the purified water from the water treatment plant 210 may be supplied to the chlor-alkali membrane process 212.

[0038] In this embodiment, the chlor-alkali film process 212 uses sodium ions (Na + It may include an ion-selective membrane configured to allow chloride ions (Cl) to flow freely through the membrane, while the membrane may contain chloride ions (Cl) - ) and hydroxide ions (OH -) is prevented from moving through the membrane. The chlor-alkali membrane process 212 may include an anode and a cathode. At the anode, chloride ions (Cl - ) from the brine solution are oxidized to form chlorine (Cl2) gas. At the cathode, water (H2O) is reduced to hydroxide ions (OH - ) and hydrogen (H2) gas, and hydroxide ions (OH - ) are released into the solution. Sodium ions (Na + ) from the brine solution flow through the membrane towards the cathode and combine with hydroxide ions (OH - ) to produce a sodium hydroxide (NaOH) solution. The sodium hydroxide (NaOH) solution can be removed as a product from the chlor-alkali membrane process 212.

[0039] In embodiments, the chlor-alkali membrane process 212 can reduce the sodium chloride (NaCl) concentration of the brine. The outlet stream from the chlor-alkali membrane process 212 can be reduced, for example, to a sodium chloride (NaCl) concentration of benign seawater concentration (e.g., 3.5%) and further processed in a downstream chlor-alkali membrane cell or returned to the water treatment plant 210 for supply.

[0040] In embodiments, the chlorine (Cl2) gas and hydrogen (H2) gas generated in the chlor-alkali membrane process 212 can be removed as products that are stored, sold, or used in further resource generation such as a hydrochloric acid production plant 214.

[0041] In embodiments, the water treatment plant 210, the chlor-alkali membrane process 212, and the hydrochloric acid production plant 214 are configured to receive power from the power generation plant 202.

[0042] In embodiments, IES200 may include a hydrogen production plant 216, such as the hydrogen production process 500 shown in Figure 5, according to embodiments of the present disclosure. In embodiments, carbon monoxide (CO) from a carbon dioxide conversion plant 208 is supplied to the hydrogen production plant 216 together with solid sodium hydroxide (NaOH). In embodiments, a sodium hydroxide (NaOH) solution from, for example, a chlor-alkali membrane process 212 may be converted to a solid form through a drying process such as a thermal vacuum dehydration chamber. In the hydrogen production plant 216, carbon monoxide (CO) is absorbed under pressure by solid sodium hydroxide (NaOH), for example, at a temperature of 130°C and a pressure of 6-8 bar, to produce sodium formate (HCOONa). In embodiments, the sodium formate (HCOONa) may then be heated to undergo thermal decomposition, thereby producing hydrogen (H2) gas and sodium oxalate (Na2C2O4). The thermal decomposition temperature of sodium formate (HCOONa) starts at approximately 330°C.

[0043] The hydrogen (H2) produced in the hydrogen production plant 216 may be sent to downstream processes for use in resource production, stored and / or sold. Sodium oxalate (Na2C2O4), as well as any intermediates or by-products produced in the hydrogen production plant 216, may be recycled within the IES200 to optimize yield, sent to downstream processes for use in resource production, stored and / or sold. In this embodiment, the hydrogen production plant 216 is configured to receive power from the power plant 202.

[0044] In embodiments, IES200 may include a methanol production plant 218, such as a methanol production process 600 according to embodiments of the present disclosure. The methanol production plant 218 may include a highly selective copper (Cu) and zinc oxide (ZnO) catalyst (Cu / ZnO). The reaction of carbon dioxide (CO2) with hydrogen (H2) produces water, which accelerates the deactivation of the Cu / ZnO catalyst. Introducing carbon monoxide (CO) into the reaction of carbon dioxide (CO2) with hydrogen (H2) removes water via a water-gas shift (WGS) reaction. In embodiments, carbon dioxide (CO2), carbon monoxide (CO), and hydrogen (H2) are supplied to the methanol production plant 218. Carbon dioxide (CO2) and carbon monoxide (CO) may be supplied, for example, from a carbon dioxide (CO2) conversion plant 208. Hydrogen (H2) may be supplied, for example, from a hydrogen production plant 216. Methanol (CH3OH) may be stored or sold. In this embodiment, the methanol production plant 216 is configured to receive power from the power plant 202.

[0045] In embodiments, IES200 may include a control system. In a typical embodiment, IES200 has a stable power source and a saline water source from the power plant 202, which are always available in the desired amount. The concentration and presence of carbon dioxide (CO2) may vary throughout the day depending on the operating conditions of the emission source 204. The optimal production rate of sodium formate (HCOONa) and methanol (CH3OH) requires supplying the hydrogen production plant 216 with appropriate ratios of sodium hydroxide (NaOH) and carbon monoxide (CO). A closed-loop control system can be implemented to optimize the production of sodium formate (HCOONa) and methanol (CH3OH) and save power when carbon dioxide (CO2) emissions are low or absent. The process may include:

[0046] The closed-loop system can sense the carbon dioxide (CO2) concentration inside the chimney of the emission source 204 using an electrochemical carbon dioxide (CO2) sensor. For example, when carbon dioxide (CO2) comes into contact with the sensor, it reacts with the polymer surface to generate an electric charge. In other embodiments, any other type of carbon dioxide (CO2) sensor can be used.

[0047] The closed-loop control system may include a microcontroller or computer that measures the carbon dioxide (CO2) concentration with the sensors described above and adjusts the power supplied from the power plant 202 to the solid oxide electrolytic cells in the chlor-alkali membrane process 212 and the carbon dioxide (CO2) conversion plant 208 accordingly, thereby regulating the production of sodium hydroxide (NaOH). The power saved from the above process can be supplied to the power grid or to the water treatment plant 210 to produce a larger amount of clean water.

[0048] In the embodiment, the power plant 202 may be a permanent or temporary facility constructed at or near (for example, approximately 1 km from) the emission source 204, scrubber 206, carbon dioxide (CO2) conversion plant 208, water treatment plant 210, chlor-alkali membrane process 212, hydrochloric acid production plant 214, hydrogen production plant 216, and / or methanol production plant 218. In embodiments, the power plant 202 may be a mobile or partially mobile system that is moved and assembled at or near the location of the emission source 204, scrubber 206, carbon dioxide (CO2 conversion plant 208, water treatment plant 210, chlor-alkali membrane process 212, hydrochloric acid production plant 214, hydrogen production plant 216, and / or methanol production plant 218. More generally, the power plant 202 may be local to the industrial process / operation it supports (e.g., located there or nearby). For example, the power plant may be located within 0.4 km (0.25 miles), 0.8 km (0.5 miles), 3.22 km (2 miles), 4.82 km (3 miles), or 8.1 km (5 miles) of the industrial process / operation it supports. In embodiments, the power plant 202 is configured to supply a portion of the electricity to the power grid.

[0049] Figure 3 is a block diagram of a carbon dioxide (CO2) conversion plant 300 according to an embodiment of the present disclosure. In the embodiment, the carbon dioxide (CO2) conversion plant 300 may include one or more solid oxide electrolytic cells (SOECs) 302. The SOEC 302 of the present invention may be configured to carry out the electrochemical reduction of carbon monoxide (CO) and oxygen (O2) to carbon dioxide (CO2), as described, for example, in Kungas, J. Electrochem. Soc. 167, 2020 and WO2014 / 154253. In the embodiment, the electrolyte of the SOEC 302 may include solid ceramic materials, stabilized zirconia such as yttria-stabilized zirconia (YSZ, a solid solution of Y2O3 and ZrO2) and scandia-stabilized zirconia (ScSZ), and doped ceria such as gadolinia-doped ceria (abbreviated as either GDC) or samaria-doped ceria (SDC).

[0050] In this embodiment, carbon dioxide (CO2) is supplied to the fuel side 304 of the SOEC302 stack by an applied current. The fuel side 304 of the SOEC302 may include a cathode. Oxygen from the reaction is transported to the oxygen side 306 of the stack. The oxygen side 306 of the SOEC302 may also include an anode. Equation 1 shows the formula that defines the reduction of carbon dioxide (CO2) for the production of carbon monoxide (CO) and oxygen (O2).

number

[0051] In embodiments, carbon dioxide (CO2) may be used to flush the oxygen side 306. Optionally, air or nitrogen may be used to flush the oxygen side 306 of the SOEC 302 stack. In preferred embodiments, carbon dioxide (CO2) is used instead of air to flush the oxygen side 306 to reduce leakage of undesirable gases, such as nitrogen (N2), into the fuel side 304 of the SOEC 302. Flushing the oxygen side 306 of the SOEC 302 with carbon dioxide (CO2) gas has two advantages, more specifically: (1) increasing the oxygen production concentration, and (2) providing a means for supplying energy to the SOEC 302. In embodiments, the SOEC 302 operates at high temperatures (e.g., about 600°C). The inlet gas to the fuel side 304 and / or the flash gas to the oxygen side 306 may be heated, for example, in one or more auxiliary heaters before entering the SOEC 302. In embodiments, Joule heating, i.e., the heat generated when an electric current passes through SOEC302, can supply some or all of the heat required by SOEC302. In embodiments, Joule heating, auxiliary heaters, and / or heating means known in the art can be used in combination to provide optimal operating conditions for SOEC302. In embodiments, the carbon dioxide (CO2) conversion plant 208 can receive electrical and / or thermal energy from the power plant 202.

[0052] Next, the product stream from the fuel side 304 of SOEC 302, for example, the product stream containing carbon monoxide (CO) mixed with carbon dioxide (CO2), can pass through the separation process 308 to separate carbon monoxide (CO) and carbon dioxide (CO2). In embodiments, the separation process 308 may include one or more separation units such as pressure swing adsorption (PSA), temperature swing adsorption (TSA), membrane separation, and cryogenic separation techniques. The carbon dioxide (CO2) from the separation process 308 can be recycled into SOEC 302 within the carbon dioxide (CO2) conversion plant 300, for example, and / or used in downstream processes such as methanol (CH3OH) production. The carbon monoxide (CO) from the separation process 308 can be recycled into SOEC 302 within the carbon dioxide (CO2) conversion plant 300, for example, and / or used in downstream processes such as hydrogen (H2) production and methanol (CH3OH) production.

[0053] Next, the product stream from the oxygen side 306 of SOEC302, for example, a product stream containing oxygen (O2) mixed with carbon dioxide (CO2), can pass through the separation process 310 to separate oxygen (O2) and carbon dioxide (CO2). In embodiments, the separation process 310 may include one or more separation units such as PSA, adsorption, and membrane separation. The carbon dioxide (CO2) from the separation process 308 can be recycled to SOEC302, for example, within the carbon dioxide (CO2) conversion plant 300, and / or used in downstream processes such as methanol (CH3OH) production. The oxygen (O2) from the separation process 310 can be used in downstream processes, stored, further purified, and / or sold.

[0054] Figure 4 is a block diagram of a chlorine-alkali membrane process 400 according to an embodiment of the present disclosure. The chlorine-alkali membrane process 400 may use a membrane cell 404 to separate the brine solution in a first chamber 406 from the water (H2O) solution in a second chamber 408. In an embodiment, the saline water is supplied to a water treatment plant 402. The water treatment plant 402 may include a water treatment plant 210. In an embodiment, the water treatment plant 402 produces clean water and brine. In an illustrated example, saline water, such as seawater with a salinity of 3.5% sodium chloride (NaCl), is supplied to the water treatment plant 402. The water treatment plant 402 converts the saline water into clean water (e.g., with a sodium chloride (NaCl) concentration of less than 0.05%) and brine (e.g., with a sodium chloride (NaCl) concentration of 7.5%).

[0055] In the embodiment, brine from the water treatment plant 402 is supplied to a first chamber 406 of the chlorine-alkali membrane cell 404. In the embodiment, a portion of the clean water from the water treatment plant 402 may be supplied to a second chamber 408 of the chlorine-alkali membrane cell 404. A typical chlorine-alkali membrane process can handle brine concentrations of up to 26% sodium chloride (NaCl). In the embodiment, the brine from the water treatment plant 402 may contain a sodium chloride (NaCl) concentration of up to 26%. In the embodiment, the chlorine-alkali membrane process 400 may therefore include one or more chlorine-alkali membrane cells 404 configured to operate, for example, in series, in parallel, or in combination.

[0056] Chloride-alkali membrane cell 404 contains sodium ions (Na + ) may be an ion-selective membrane configured to allow chloride ions (Cl) to flow freely through the membrane between the first chamber 406 and the second chamber 408, while chloride ions (Cl) - ) and hydroxide ions (OH - ) are prevented from moving through the chlorine alkali membrane cell 404. The anode is in the first chamber 406 and the cathode is in the second chamber 408. At the anode, chloride ions (Cl) from the brine solution are prevented from moving.- ) is oxidized to form chlorine (Cl2) gas. At the cathode, hydrogen (H2O) is converted into hydroxide ions (OH - ) and hydrogen (H2) gas are reduced to hydroxide ions (OH - ) is released into the solution.

[0057] Sodium ions (Na) from brine solution in the first chamber 406 + ) flows through the membrane toward the cathode in the second chamber 408, and hydroxide ions (OH - ) is combined with to produce a sodium hydroxide (NaOH) solution. The sodium hydroxide (NaOH) solution can be removed as a product from the second chamber 408. The overall equation for the reaction of brine to electrolysis is shown in Equation 2.

number

[0058] In this embodiment, the chlorine-alkali process 400 can reduce the sodium chloride (NaCl) concentration of the brine entering the first chamber 406. The outlet flow from the first chamber 406 can be reduced to, for example, a beneficial seawater concentration of sodium chloride (NaCl) (e.g., 3.5%). The output from the first chamber 406 can be further treated in a downstream chlorine-alkali membrane cell 404, supplied back to the water treatment plant 402 process, or safely discharged back into an environment such as an ocean, sea, or lake containing the same or a higher concentration of sodium chloride (NaCl) as the output flow.

[0059] In this embodiment, the chlorine (Cl2) gas and hydrogen (H2) gas generated in the chlor-alkali membrane process 400 may be stored, sold, or removed as products used in further resource production, such as in a hydrochloric acid production plant 410. For example, the chlorine (Cl2) gas and hydrogen (H2) gas may be used to generate hydrogen chloride (HCl) gas for conversion to hydrochloric acid (HCl). The reaction equation is shown in Equation 3.

number

[0060] The chlor-alkali membrane process 400 can be approximately 40 times more energy-intensive than the reverse osmosis (RO) desalination process. In this embodiment, the water treatment plant 402, the chlor-alkali membrane cell 404, and the hydrochloric acid production plant 410 are configured to receive electricity from the power plant 202.

[0061] Figure 5 is a block diagram of a hydrogen production process 500 according to an embodiment of the present disclosure. Sodium formate (HCOONa) can be produced by reacting solid sodium hydroxide (NaOH) with carbon monoxide (CO) under pressure, and hydrogen (H2) gas can be produced through the thermal decomposition of sodium formate (HCOONa). See, for example, U.S. Patent No. 2,281,715, Kumar, et al., Catalysts ISSN 2073-4344, Nov. 27, 2012. In the embodiment, for example, a sodium hydroxide (NaOH) solution from a chlor-alkali membrane process 400 can be converted to a solid form through a drying process such as a thermal vacuum dehydration chamber 502. The solid sodium hydroxide (NaOH) can then be supplied to a hydrogen production plant 504, where it is introduced into carbon monoxide (CO) in a reaction chamber 506. Sodium formate (HCOONa) is produced by the reaction shown in Equation 4.

number

[0062] In reaction chamber 506, carbon monoxide (CO) is absorbed by sodium hydroxide (NaOH). The operating conditions of reaction chamber 506 can be optimized for yield and efficiency using techniques known in the art. For example, reaction chamber 506 can be operated at a temperature of 130°C and a pressure of 6-8 bar.

[0063] In this embodiment, sodium formate (HCOONa) may be supplied to the pyrolysis chamber 508. The sodium formate (HCOONa) slowly decomposes by hydrogen loss, and at 330°C, after the reaction shown in Equation 5, it produces sodium oxalate (Na2C2O4).

number

[0064] The rate of the decomposition reaction increases significantly at 400°C, associated with a large exothermic change. Subsequently, when heated above 440°C, sodium oxalate (Na2C2O4) decomposes into sodium carbonate (Na2CO3) and carbon monoxide (CO). Both the heating rate and the maximum temperature significantly affect the yield of sodium oxalate (Na2C2O4). To maximize the yield of sodium oxalate (Na2C2O4), the optimal temperature for thermal decomposition is 400°C to 420°C, and sodium formate (HCOONa) should be heated as rapidly as possible to shorten the reaction time. Overheating can cause rapid decomposition of sodium oxalate (Na2C2O4), potentially producing sodium carbonate (Na2CO3) and carbon monoxide (CO) gas. The hydrogen (H2) generated in the hydrogen production plant 504 can be sent to downstream processes for use in resource production, or it can be stored and / or sold. Sodium oxalate (Na2C2O4), and any intermediates or by-products generated in the hydrogen production plant 504, such as sodium formate (HCOONa), sodium carbonate (Na2CO3), and carbon monoxide (CO), may be sent to downstream processes for use in resource production, stored, and / or sold. In embodiments, the hydrogen production process 500 is configured to receive electricity from the power plant 202.

[0065] Figure 6 is a block diagram of a methanol production process 600 according to an embodiment of the present disclosure. Methanol (CH3OH) can be produced by directly hydrogenating pure carbon dioxide (CO2) with hydrogen (H2) due to its high selectivity over conventional copper (Cu) and zinc oxide (ZnO) catalysts (Cu / ZnO). The reaction rate is much lower than that of synthesis gas feed due to thermodynamic limits. This synthesis from pure carbon dioxide (CO2) is also complicated due to increased water formation. In the absence of carbon monoxide (CO), water is also produced as a byproduct of carbon dioxide (CO2) hydrogenation. Increased water formation leads to dynamic inhibition and accelerated deactivation of the Cu / ZnO catalyst. Therefore, the solution is to introduce carbon monoxide (CO) into the reaction chamber and remove water via a water-gas shift (WGS) reaction so that methanol (CH3OH) production can continue. The reactions for methanol (CH3OH) production are shown in equations 6-8.

number

[0066] The reaction is carried out with a Cu / ZnO catalyst at a temperature of 200-300°C and a pressure of 50-100 bar. Equation 8 is the aqueous shift reaction (WSR). Even though methanol (CH3OH) can be produced by directly hydrogenating pure carbon dioxide (CO2) with hydrogen (H2) via Equations 6 and 7 using conventional Cu / ZnO catalysts, the reaction rate will terminate immediately after the start due to the continuous formation of water, which leads to dynamic inhibition and accelerated deactivation of the Cu / ZnO catalyst. The presence of carbon monoxide (CO) during the reaction is crucial for continuing the WSR in order to maintain synthesis at low temperatures and pressures without deactivating the catalyst.

[0067] In this embodiment, carbon dioxide (CO2), carbon monoxide (CO), and hydrogen (H2) are supplied to the methanol synthesis reaction chamber 602. The carbon dioxide (CO2) and carbon monoxide (CO) may be supplied, for example, from a carbon dioxide (CO2) conversion plant 300. The hydrogen (H2) may be supplied, for example, from a hydrogen production process 500. Methanol (CH3OH) may be stored or sold. In this embodiment, the methanol production process 600 is configured to receive power from a power plant 202.

[0068] Figure 7 is a schematic diagram of a nuclear power plant system 750 ("Power Plant System 750") comprising a plurality of reactors 700 (each individually identified as reactors 1 to 12, 700a to l) according to an embodiment of the present technology. The Power Plant System 750 may be a permanent or temporary installation constructed at or near (e.g., approximately 1 km from) the site of an industrial process facility, or it may be a mobile or partially mobile system that is moved to and assembled at or near the site of an industrial process facility. More generally, the power plant may be local to the industrial process / operation it supports (e.g., located there or near there). For example, the power plant may be located within 0.4 km (0.25 miles), 0.8 km (0.5 miles), 3.22 km (2 miles), 4.82 km (3 miles), or 8.1 km (5 miles) of the industrial process / operation it supports. In this embodiment, the power plant system 750 is configured to supply a portion of the electricity to the power grid.

[0069] Each of the reactors 700 may be similar to or identical to the reactor systems 800 and / or reactor systems 900 described below in detail with reference to Figures 8 and 9. The power plant system 750 may be "modular" in that each of the reactors 700 may operate separately to provide output such as electricity or steam. In embodiments, the power plant system may include small modular reactors (SMRs). The power plant system 750 may include fewer than 12 reactors 700 (e.g., 2, 3, 4, 5, 6, 7, 8, 9, 10, or 11 reactors 700) or more than 12 reactors 700. The power plant system 750 may be a permanent installation or it may be mobile (e.g., mounted on a truck, tractor, mobile platform, and / or similar). In the illustrated embodiment, each of the reactors 700 is located within a common housing 751, such as a reactor plant building, and can be controlled and / or monitored via a control room 752.

[0070] Each of the reactors 700 can be connected to a corresponding power conversion system 740 (each individually identified as the 1st to 12th power conversion systems 740a to l). The power conversion system 740 may include one or more devices that generate electricity or any other form of usable electricity from the steam generated by the reactor 700. For example, the power conversion system 740 may include features similar to or identical to the power conversion system 840 described in detail below with reference to Figure 8. In some embodiments, multiple reactors 700 can be connected to the same power conversion system 740, and / or one or more reactors 700 can be connected to multiple power conversion systems 740 such that there is no one-to-one correspondence between the reactors 700 and the power conversion systems 740.

[0071] The power conversion system 740 may be further connected to a power transmission system 754, for example, via a power bus 753. The power transmission system 754 and / or power bus 753 may include one or more transmission lines, transformers, and / or similar for regulating the current, voltage, and / or other characteristics of the electricity generated by the power conversion system 740. The power transmission system 754 may route the electricity to one or more end uses, such as different electrical loads of an integrated energy system, via a plurality of electrical output paths 755 (individually identified as electrical output paths 755a-n), as described in more detail herein.

[0072] The power plant system 750 can be configured to supply electricity to the water treatment plant 210 in a first operating state (for example, via one or more of the electrical output paths 755 from the power transmission system 754). The water treatment plant 210 can route the generated high-quality water to the power plant system 750, which can use the water to generate high-quality steam. For example, the generated water can be used as a secondary coolant in one or more steam generators of the reactor 700. In some embodiments, the water treatment plant 210 can be omitted, and the power plant system 750 can utilize water from other sources to generate steam.

[0073] Each of the reactors 700 can be further connected to a steam transfer system 756, for example, via a steam bus 757. The steam bus 757 can route steam generated from the reactors 700 to the steam transfer system 756, which can then route the steam to one or more end uses, such as different steam inputs in an integrated energy system, via a plurality of steam output routes 758 (individually identified as steam output routes 758a to n), as described in more detail below.

[0074] In some embodiments, the reactor 700 can be individually controlled (e.g., via a control room 752) to supply steam to a steam transmission system 756 and / or to a corresponding power conversion system 740 to supply electricity to a power transmission system 754. In some embodiments, the reactor 700 is configured to supply steam to either a steam bus 757 or a corresponding power conversion system 740, and can switch quickly and efficiently between supplying steam to either. Thus, in some aspects of the art, the reactor 700 can be controlled modularly and flexibly so that the power plant system 750 can supply electricity through different levels / amounts of power transmission systems 754 and / or steam through steam transmission systems 756. For example, if the power plant system 750 is used to supply electricity and steam to one or more industrial processes, such as various components of an integrated energy system described in detail below, the reactor 700 can be controlled to meet the different electrical and steam requirements of the industrial processes.

[0075] As an example, during a first operating state of an integrated energy system using a power plant system 750, a first subset of reactors 700 (e.g., reactors 1 to 6, 700a to f) may be configured to supply steam to a steam transmission system 756 for use in the first operating state of the integrated energy system, while a second subset of reactors 700 (e.g., reactors 7 to 12, 700g to l) may be configured to supply steam to a corresponding power conversion system 740 (e.g., power conversion systems 7 to 12, 740g to l) to generate electricity for the first operating state of the integrated energy system. Subsequently, in a second operating state of the integrated energy system where different (e.g., more or less) amounts of steam and / or electricity are required, some or all of the first subset of the reactor 700 can be switched to supply steam to the corresponding power conversion systems 740 (e.g., power conversion systems 740g-l, 7th-12th) and / or to supply steam to the steam transmission system 756, in order to vary the amount of steam and electricity generated to match the requirements / demands of the second operating state. Other variations in steam and electricity generation are possible based on the needs of the integrated energy system. That is, the reactor 700 can be dynamically / flexibly controlled during other operating states of the integrated energy system to meet the steam and electricity requirements of the operating state.

[0076] In contrast, some conventional nuclear power plant systems can typically generate either a fixed amount of steam or electricity for output, and cannot be modularly controlled to provide varying levels of steam and electricity for output. Furthermore, switching between steam and electricity generation is typically difficult (e.g., expensive, time-consuming) in conventional nuclear power plant systems. Specifically, for example, in prototype large-scale nuclear power plant systems, switching between steam and electricity generation is typically extremely time-consuming.

[0077] The reactor 700 can be individually controlled via one or more operators and / or via a computer system. Therefore, many embodiments of the techniques described herein may take the form of computer or machine or controller executable instructions, including routines executed by a programmable computer or controller. Those skilled in the art will understand that this technique can be practiced on computer / controller systems other than those shown and described herein. This technique can be embodied in a special-purpose computer, controller, or data processor that is specifically programmed, configured, or constructed to implement one or more of the computer executable instructions described below. Therefore, the terms “computer” and “controller” as used herein refer to any data processor and may include Internet appliances and handheld devices (including palmtop computers, wearable computers, cellular or mobile phones, multiprocessor systems, processor-based or programmable home electronic devices, network computers, minicomputers, and similar). Information handled by these computers may be presented on any suitable display medium, including liquid crystal displays (LCDs).

[0078] This technology can also be implemented in a distributed environment in which tasks or modules are performed by remote processing devices linked through a communication network. In a distributed computing environment, program modules or subroutines may reside in local and remote memory storage devices. Embodiments of the technology described herein may be stored or distributed on computer-readable media, including magnetically or optically readable or removable computer disks, and may be electronically distributed over a network. Specific data structures and data transfer for embodiments of this technology are also included within the scope of the embodiments of the technology.

[0079] Figures 8 and 9 illustrate a typical reactor that may be included in embodiments of the present technology. Figure 8 is a partial schematic, partial cross-sectional view of a reactor system 800 configured according to embodiments of the present technology. The system 800 may include a power module 802 having a core 804 in which a controlled nuclear reaction takes place. Thus, the core 804 may include one or more fuel assemblies 801. The fuel assemblies 801 may include fissile and / or other suitable materials. The heat from the reaction generates steam in a steam generator 830, where the steam is directed to a power conversion system 840. The power conversion system 840 generates power and / or provides other useful outputs such as superheated steam. A sensor system 850 is used to monitor the operation of the power module 802 and / or other system components. Data acquired from the sensor system 850 can be used to control the power module 802 in real time and / or to update the design of the power module 802 and / or other system components.

[0080] The power module 802 then includes a containment vessel 810 (e.g., a radiation shielding vessel or radiation shielding container) that houses / encloses a reactor vessel 820 (e.g., a reactor pressure vessel or reactor pressure container) that houses the reactor core 804. The containment vessel 810 can be housed in a power module bay 856. The power module bay 856 may include a cooling pool 803 filled with water and / or another suitable cooling fluid. The majority of the power module 802 can be located below the surface 805 of the cooling pool 803. Thus, the cooling pool 803 can act as a heat sink, for example, in the event of a system malfunction.

[0081] The volume between the reactor vessel 820 and the containment vessel 810 can be partially or completely evacuated to reduce heat transfer from the reactor vessel 820 to the surrounding environment (e.g., the cooling pool 803). However, in other embodiments, the volume between the reactor vessel 820 and the containment vessel 810 can be at least partially filled with gases and / or liquids that increase heat transfer between the reactor vessel 820 and the containment vessel 810. For example, the volume between the reactor vessel 820 and the containment vessel 810 can be at least partially filled (e.g., filled with primary coolant 807) during emergency operations.

[0082] Within the reactor vessel 820, the primary coolant 807 carries heat from the core 804 to the steam generator 830. For example, as illustrated by the arrows located within the reactor vessel 820, the primary coolant 807 is heated in the core 804 toward the bottom of the reactor vessel 820. The heated primary coolant 807 (e.g., water with or without additives) rises from the core 804 through the core shroud 806 to the riser tube 808. The hot, buoyant primary coolant 807 continues to rise through the riser tube 808 and then exits the riser tube 808 and passes downward through the steam generator 830. The steam generator 830 includes a number of conduits 832 arranged circumferentially around the riser tube 808, for example in a helical pattern, as schematically shown in Figure 8. The descending primary coolant 807 transfers heat to the secondary coolant (e.g., water) in the conduit 832 and descends to the bottom of the reactor vessel 820, where the cycle is restarted. The cycle can be driven by the change in the buoyancy of the primary coolant 807, thus reducing or eliminating the need for pumps to move the primary coolant 807.

[0083] The steam generator 830 may include a feedwater header 831 into which incoming secondary coolant enters the steam generator conduit 832. The secondary coolant rises through the conduit 832, is converted into vapor (e.g., steam), and collected in the steam header 833. The steam exits the steam header 833 and is directed to the power conversion system 840.

[0084] The power conversion system 840 may include one or more steam valves 842 that regulate the passage of high-pressure, high-temperature steam from the steam generator 830 to the steam turbine 843. The steam turbine 843 converts the thermal energy of the steam into electricity via a generator 844. The low-pressure steam exiting the turbine 843 is condensed in a condenser 845 and then directed to one or more feedwater valves 841 (e.g., via a pump 846). The feedwater valves 841 control the rate at which the feedwater re-enters the steam generator 830 via a feedwater header 831. In other embodiments, the steam from the steam generator 830 can be routed for direct use in industrial processes such as hydrogen and oxygen production plants, chemical production plants, and / or similar, as described in detail in this application. Thus, the steam exiting the steam generator 830 can bypass the power conversion system 840.

[0085] The power module 802 includes several control systems and associated sensors. For example, the power module 802 may include a hollow cylindrical reflector 809 that returns neutrons into the core 804 to further accelerate the nuclear reaction occurring therein. Control rods 813 are used to regulate the nuclear reaction and are driven via a fuel rod driver 815. The pressure inside the reactor vessel 820 can be controlled via a pressurizer plate 817 by controlling the pressure in a pressurized volume 819 located above the pressurizer plate 817 (this can also function to direct the primary coolant 807 downward through the steam generator 830).

[0086] The sensor system 850 may include, for example, one or more sensors 851 located at various positions within and / or elsewhere in the power module 802 to identify operating parameter values ​​and / or changes in parameter values. The data collected by the sensor system 850 can then be used to control the operation of system 800 and / or to make design changes for system 800. For sensors located within the containment 810, the sensor link 852 directs data from the sensor to the flange 853 (where the sensor link 852 exits the containment 810) and to the sensor junction box 854. From there, the sensor data can be routed via the data bus 855 to one or more controllers and / or other data systems.

[0087] Figure 9 is a partial schematic, partial cross-sectional view of a reactor system 900 ("System 900") configured according to an additional embodiment of the present technology. In some embodiments, System 900 may include several features that are at least generally similar in structure and function to, or identical in structure and function to, the corresponding features of System 800, which are described in detail above with reference to Figure 8, and may operate in a manner generally similar to or identical to System 800.

[0088] In the illustrated embodiments, the system 900 includes a furnace vessel 920 and a containment vessel 910 surrounding / enclosing the furnace vessel 920. In some embodiments, the furnace vessel 920 and the containment vessel 910 may be substantially cylindrical or capsule-shaped. The system 900 further includes a plurality of heat pipe layers 911 within the furnace vessel 920. In the illustrated embodiments, the heat pipe layers 911 are spaced apart from each other and stacked. In some embodiments, the heat pipe layers 911 can be mounted / secured to a common frame 912, a portion of the furnace vessel 920 (e.g., its walls), and / or other suitable structures within the furnace vessel 920. In other embodiments, the heat pipe layers 911 can be stacked directly on top of each other such that each heat pipe layer 911 supports and / or is supported by one or more of the other layers of heat pipe layers 911.

[0089] In the illustrated embodiments, the system 900 further includes a shielding or reflector region 914 that at least partially surrounds the core region 916. The heat pipe layer 911 may be circular, linear, polygonal, and / or have other shapes, and as a result, the core region 916 has a corresponding three-dimensional shape (e.g., cylindrical, spherical). In some embodiments, the core region 916 is separated from the reflector region 914 by a core partition 915, such as a metal wall. The core region 916 may include one or more fuel sources, such as fissile material, for heating the heat pipe layer 911. The reflector region 914 may include one or more materials configured to contain / reflect products generated by burning fuel within the core region 916 during the operation of the system 900. For example, the reflector region 914 may include a liquid or solid material configured to reflect neutrons and / or other fission products radially inward toward the core region 916. In some embodiments, the reflector region 914 can completely surround the core region 916. In other embodiments, the reflector region 914 can partially surround the core region 916. In some embodiments, the core region 916 can include control material 917 such as a moderator and / or coolant. The control material 917 can at least partially surround the heat pipe layer 911 within the core region 916 and transfer heat between them.

[0090] In the illustrated embodiments, the system 900 further includes at least one heat exchanger 930 (e.g., a steam generator) arranged around a heat pipe layer 911. The heat pipe layer 911 may extend at least partially from the core region 916 into the reflector region 914 and be thermally coupled to the heat exchanger 930. In some embodiments, the heat exchanger 930 may be located outside the reflector region 914 or partially within the reflector region 914. The heat pipe layer 911 provides a heat transfer path from the core region 916 to the heat exchanger 930. For example, each heat pipe layer 911 may include an array of heat pipes that provide a heat transfer path from the core region 916 to the heat exchanger 930. When the system 900 is operating, fuel in the core region 916 can heat and vaporize fluids in the heat pipes within the heat pipe layer 911, and the fluids can carry heat to the heat exchanger 930. The heat pipes within the heat pipe layer 911 can then return the fluid toward the core region 916 by suction, gravity, and / or other means of reheating and vaporizing.

[0091] In some embodiments, the heat exchanger 930 may be analogous to the steam generator 830 in Figure 8 and may include, for example, one or more helical coil tubes winding around a heat pipe layer 911. The tubes of the heat exchanger 930 contain or can contain a working fluid (a coolant such as water or another fluid) that carries heat from the heat pipe layer 911 out of the furnace vessel 920 and containment vessel 910 for use in generating electricity, steam, and / or the like. For example, in the embodiment illustrated, the heat exchanger 930 is operably connected to a turbine 943, a generator 944, a condenser 945, and a pump 946. As the temperature of the working fluid in the heat exchanger 930 rises, the working fluid may begin to boil and vaporize. The working fluid (e.g., steam) may be used to drive the turbine 943 and convert the thermal potential energy of the working fluid into electrical energy via the generator 944. The condenser 945 can condense the working fluid after it has passed through the turbine 943, and the pump 946 can direct the working fluid back to the heat exchanger 930, where the working fluid can initiate another thermal cycle. In other embodiments, the steam from the heat exchanger 930 can be routed for direct use in industrial processes such as resource generation plants, as described in detail above. Thus, the steam leaving the heat exchanger 930 can bypass the turbine 943, generator 944, condenser 945, pump 946, etc.

[0092] Figure 10 illustrates an example of process 1000 for producing methanol. In various examples, process 1000 can be carried out by an integrated energy system (IES), such as IES100 and 200. The IES may include power plants, such as power plants 102, 202, and power plant system 750. In embodiments, the power plants include nuclear modules. The IES may also include resource generation plants, such as resource generation plant 108. In embodiments, the resource generation plant may include one or more chemical generation plants or subplants. The resource generation plant may include an emission source, such as emission source 204; a scrubber, such as scrubber 206; a carbon dioxide (CO2) conversion plant, such as carbon dioxide (CO2) conversion plant 208; a water treatment plant, such as water treatment plant 210; a chlorine-alkali membrane process, such as chlorine-alkali membrane process 212; a hydrochloric acid generation plant, such as hydrochloric acid generation plant 214; a hydrogen generation plant, such as hydrogen generation plant 216; and a methanol generation plant, such as methanol generation plant 218. In the embodiment, the resource generation plan and / or chemical generation plant and subplant are part of process 1000 configured to receive electricity from a power plant. In the embodiment, the power plant is configured to supply power to a water treatment plant, an electrolytic cell, and a reaction chamber. In the embodiment, the nuclear module is local to the emission source, water treatment plant, electrolytic cell, resource generation plant, or reaction chamber.

[0093] In 1002, carbon dioxide (CO2) is received from emission sources such as natural gas or coal-fired power plants, chemical product production plants, oil refineries, ore processing plants, or steel processing plants.

[0094] In 1004, the first portion of carbon dioxide (CO2) is converted to carbon monoxide (CO). For example, carbon dioxide (CO2) is converted to carbon monoxide (CO) in a solid oxide electrolytic cell (SOEC). In embodiments, the SOEC is further configured to convert carbon dioxide (CO2) to carbon monoxide (CO) and oxygen (O2).

[0095] In step 1006, sodium hydroxide (NaOH) is received in process 1000. In the embodiment, sodium hydroxide (NaOH) is received from a chlor-alkali membrane cell. In the embodiment, the chlor-alkali membrane cell converts brine, which is a sodium chloride (NaCl) solution from a water treatment plant, into sodium hydroxide (NaOH). In the embodiment, the water treatment plant includes reverse osmosis for producing clean water and brine. Brine from the water treatment plant can be supplied to the chlor-alkali membrane cell to produce sodium hydroxide.

[0096] In 1008, carbon monoxide (CO) and sodium hydroxide (NaOH) are combined. In this embodiment, carbon monoxide (CO) and sodium hydroxide (NaOH) react to form sodium formate (HCOONa).

[0097] In 1010, hydrogen (H2) gas is produced by the thermal decomposition of sodium formate. The products obtained from the thermal decomposition of sodium formate (HCOONa) include sodium oxalate (Na2C2O4).

[0098] In 1012, a reaction chamber is used to combine the second part of carbon dioxide (CO2), carbon monoxide (CO), and hydrogen (H2).

[0099] In 10¹⁴, methanol is produced from the reaction of carbon dioxide (CO₂), carbon monoxide (CO), and hydrogen (H₂).

[0100] conclusion While the above inventions are described in relation to specific embodiments, it should be understood that the scope of the invention is not limited to these specific embodiments. Other modifications and changes adapted to suit specific operating requirements and environments will be obvious to those skilled in the art, and therefore the invention is not considered to be limited to the embodiments selected for disclosure purposes, but rather encompass all modifications and changes that do not depart from the true spirit and scope of the invention.

[0101] This application describes embodiments having certain structural features and / or methodological actions, but it should be understood that the claims are not necessarily limited to the specific features or actions described. Rather, the specific features and actions are merely illustrative embodiments that fall within the scope of the claims.

[0102] Exemplary clause A. An integrated energy system (IES) comprising: a power plant; an emission source that provides carbon dioxide; a water treatment plant configured to produce sodium hydroxide from brine; an electrolytic cell configured to convert a first portion of carbon dioxide into carbon monoxide; a resource generation plant configured to combine carbon monoxide with sodium hydroxide to produce hydrogen gas; and a reaction chamber configured to receive a second portion of carbon dioxide, carbon monoxide, and hydrogen to produce methanol.

[0103] B. The IES described in Example A, wherein the power plant is configured to supply power to a water treatment plant, an electrolytic cell, a resource generation plant, and a reaction chamber.

[0104] C. IESs as described in Example A or B, where the power plant includes a nuclear module.

[0105] D. The IES described in Example C, wherein the nuclear module is located locally to the emission source, water treatment plant, electrolytic cell, resource generation plant, or reaction chamber.

[0106] E. IESs as described in any of Examples A to D, whose emission source includes a natural gas or coal-fired power plant, a chemical product production plant, an oil refinery, an ore processing plant, or a steel processing plant.

[0107] F. An IES as described in any of Examples A to E, wherein saltwater undergoes reverse osmosis in a water treatment plant to produce purified water and brine.

[0108] G. Brine is supplied to a chlorinated alkali membrane cell to produce sodium hydroxide, as described in Example F of the IES.

[0109] H. IESs as described in any of Examples A to G, wherein the electrolytic cell is further configured to convert carbon dioxide into oxygen.

[0110] I. An IES as described in any of Examples A to H, wherein the resource generation plant is further configured to produce sodium oxalate.

[0111] J. A chemical processing plant comprising one or more subplants configured to receive carbon dioxide from an emission source, convert the first part of the carbon dioxide into carbon monoxide, receive sodium hydroxide, combine the carbon monoxide and sodium hydroxide to produce hydrogen gas, and use a reaction chamber to combine the second part of the carbon dioxide, carbon monoxide, and hydrogen to produce methanol.

[0112] K. A chemical processing plant as described in Example J, whose emission source includes a natural gas or coal-fired power plant, a chemical product production plant, an oil refinery, an ore processing plant, or a steel processing plant.

[0113] L. A chemical treatment plant as described in example J or K, in which carbon dioxide is converted to carbon monoxide in a solid oxide electrolytic cell.

[0114] M. A chemical treatment plant as described in any of Examples J to L, in which sodium hydroxide is received from a chlorine-alkali membrane cell.

[0115] N. A chlorinated alkali membrane cell converts brine to sodium hydroxide in the chemical treatment plant described in Example M.

[0116] A chemical treatment plant as described in Example N, in which O. brine is produced in a desalination plant.

[0117] P. A desalination plant, including reverse osmosis, is a chemical treatment plant as described in Example O.

[0118] Q. A method for producing methanol, comprising: receiving carbon dioxide from an emission source; converting the first part of the carbon dioxide into carbon monoxide; receiving sodium hydroxide; combining carbon monoxide and sodium hydroxide to produce hydrogen gas; and in a reaction chamber, combining the second part of the carbon dioxide, carbon monoxide, and hydrogen to produce methanol.

[0119] R. The method according to Example Q, in which carbon dioxide is converted to carbon monoxide in a solid oxide electrolytic cell.

[0120] S. The method according to example Q or R, wherein sodium hydroxide is received from a chlorine alkali membrane cell.

[0121] The method according to Example S, wherein a chlorinated alkali membrane cell converts brine to sodium hydroxide.

Claims

1. An integrated energy system (IES), Power plants and Sources of carbon dioxide emissions, A water treatment plant configured to produce sodium hydroxide from saltwater, An electrolytic cell configured to convert the first portion of the carbon dioxide into carbon monoxide, A resource generation plant configured to produce hydrogen gas by combining carbon monoxide with sodium hydroxide, An integrated energy system (IES) comprising: a reaction chamber configured to receive a second portion of carbon dioxide, carbon monoxide, and hydrogen to produce methanol.

2. The IES according to claim 1, wherein the power plant is configured to supply power to the water treatment plant, the electrolytic cell, the resource generation plant, and the reaction chamber.

3. The IES according to claim 1, wherein the power plant comprises a nuclear module.

4. The IES according to claim 3, wherein the nuclear module is located locally with respect to the emission source, the water treatment plant, the electrolytic cell, the resource generation plant, or the reaction chamber.

5. The IES according to claim 1, wherein the emission source includes a natural gas or coal-fired power plant, a chemical product production plant, an oil refinery, an ore processing plant, or a steel processing plant.

6. The IES according to claim 1, wherein the saltwater undergoes reverse osmosis in the water treatment plant to produce purified water and brine.

7. The IES according to claim 6, wherein the brine is supplied to a chlorine-alkali membrane cell to produce sodium hydroxide.

8. The IES according to claim 1, wherein the electrolytic cell is further configured to convert carbon dioxide into oxygen.

9. The IES according to claim 1, wherein the resource generation plant is further configured to produce sodium oxalate.

10. It is a chemical processing plant, Receiving carbon dioxide from emission sources, The first portion of the carbon dioxide is converted to carbon monoxide, Receive sodium hydroxide, By combining the carbon monoxide and sodium hydroxide, hydrogen gas is produced. A chemical processing plant comprising one or more subplants configured to use a reaction chamber to combine the second portion of carbon dioxide, the carbon monoxide, and the hydrogen to produce methanol.

11. The chemical processing plant according to claim 10, wherein the emission source includes a natural gas or coal-fired power plant, a chemical product production plant, an oil refinery, an ore processing plant, or a steel processing plant.

12. The chemical treatment plant according to claim 10, wherein the carbon dioxide is converted to carbon monoxide in a solid oxide electrolytic cell.

13. The chemical treatment plant according to claim 10, wherein the sodium hydroxide is received from a chlorine-alkali membrane cell.

14. The chemical treatment plant according to claim 13, wherein the chlorine-alkali membrane cell converts brine to sodium hydroxide.

15. The chemical treatment plant according to claim 14, wherein the brine is produced in a desalination plant.

16. The chemical treatment plant according to claim 15, wherein the desalination plant includes reverse osmosis.

17. A method for producing methanol, Receiving carbon dioxide from emission sources, Converting the first portion of the carbon dioxide into carbon monoxide, Receiving sodium hydroxide, Combining the carbon monoxide and sodium hydroxide to produce hydrogen gas, A method comprising producing methanol in a reaction chamber by combining the second portion of carbon dioxide, the carbon monoxide, and the hydrogen.

18. The method according to claim 17, wherein the carbon dioxide is converted to carbon monoxide in a solid oxide electrolytic cell.

19. The method according to claim 17, wherein the sodium hydroxide is received from a chlor-alkali membrane cell.

20. The method according to claim 19, wherein the chlorine-alkali membrane cell converts brine to sodium hydroxide.

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