Single casing syngas compression for methanol synthesis

Abstract

Disclosed herein is a system for compressing a working fluid. The system includes a rotary driver in rotary communication with a shaft of a compressor. The compressor includes: a casing arrangement; and a first compressor section in the casing arrangement, the first compressor section including a multiple-stages with a rotating impeller running at a high speed. At least one of the casing arrangement or the first compressor impeller includes a material that is resistant to corrosion by carbon dioxide or hydrogen. The compressor is operative to compress syngas to a pressure in the range of 50 to 120 bar.

Description

71 PRO-511231 -W0-2_BHI0606PCTSINGLE CASING SYNGAS COMPRESSION FOR METHANOL SYNTHESISCROSS REFERENCE TO RELATED APPLICATIONSThis application claims the benefit of IT Application No. 102024000029175, filed on December 19, 2024, which is incorporated herein by reference in its entirety.TECHNICAL FIELD

[0001] The present disclosure relates to compressors. Specifically, embodiments disclosed herewith concern integral compressor arrangements and methods of manufacture thereof.BACKGROUND ART

[0002] In several industrial applications a need exists to boost the pressure of a gaseous flow. Dynamic compressors, such as in particular centrifugal compressors, are often used to compress a gaseous flow. The compressor is driven by mechanical power, which is delivered by a driver, such as an electric motor.

[0003] A valuable aspect in the design of combined compressor configurations includes an efficient energy recovery and optimal operation of the compressor stages. Continuous efforts are therefore being made in order to improve efficiency and reliability of operation of these machines.SUMMARY

[0004] Disclosed herein is a system for compressing a working fluid, the system comprising a rotary driver in rotary communication with a shaft of a compressor; where the compressor comprises: a casing arrangement; and a first compressor section in the casing arrangement, the first compressor section comprising a multiple- stages with a rotating impeller running at a high speed; where at least one of the casing arrangement or the first compressor impeller comprises a material that is resistant to corrosion by carbon dioxide or hydrogen; where the compressor is operative to compress syngas to a pressure in the range of 50 to 120 bar.

[0005] Disclosed herein too is a method of pressurizing a working fluid, the method of pressurizing the working fluid comprising transporting a working fluid comprising syngas and / or methanol to a compressor; where the compressor comprises: a casing arrangement; and71 PRO-511231 -W0-2_BHI0606PCT a first compressor section, the first compressor section comprising a multiple- stages with a rotating impeller running at a high speed; where at least one of the casing arrangement or the first compressor impeller comprises a material that is resistant to corrosion by carbon dioxide or hydrogen, pressurizing the working fluid to a first pressure in the first compressor section; transporting the working fluid at the first pressure to a second compressor section; and pressurizing the working fluid to a second pressure in the second compressor section; where the second pressure is greater than the first pressure; and where the second pressure is operative to facilitate a conversion of syngas to methanol.

[0006] A system for compressing a working fluid, the system comprising a first charge gas compressor, a syngas purification and reformation system that lies downstream of the charge gas compressor; a methanol synthesis system that converts the syngas into methanol; and a methanol recycle system that lies downstream of the methanol synthesis system; where the methanol synthesis system and the methanol recycle system lie downstream of the syngas purification and reformation system; and where the methanol synthesis system comprises a second compressor and a methanol converter; where the second compressor comprises: a rotary driver in rotary communication with a shaft of the second compressor; a casing arrangement; and a first compressor section in the casing arrangement, where the first compressor section comprises a multiple- stages with a rotating impeller running at a high speed; where at least one of the casing arrangement or the first compressor impeller comprises a material that is resistant to corrosion by carbon dioxide or hydrogen.

[0007] In an embodiment, the first compressor section is operative to perform a first stage of compression on the working fluid and where the additional compressor sections (e.g., the second compressor section and / or the third compressor section) are operative to perform a second stage of compression and / or a third stage of compression respectively on the working fluid. Each succeeding stage of compression includes greater pressures than the preceding stage of compression.BRIEF DESCRIPTION OF THE DRAWINGS

[0008] A more complete appreciation of the disclosed embodiments of the invention and many of the attendant advantages thereof will be readily obtained as the same becomes better understood by reference to the following detailed description when considered in connection with the accompanying drawings, wherein:

[0009] FIG. 1 is a schematic illustration of a methanol conversion system;71 PRO-511231 -W0-2_BHI0606PCT

[0010] FIG. 2 is a schematic illustration of an exemplary system for compressing syngas and / or methanol;

[0011] FIG. 3 depicts an exemplary embodiment of the compressor; and

[0012] FIG. 4 is a schematic illustration of a green methanol conversion system.DETAILED DESCRIPTION

[0013] Disclosed herein is a system and a method for compressing syngas (that contains hydrogen, carbon monoxide and carbon dioxide) and / or methanol using a compressor having multiple stages. In an embodiment, the compressor includes at least two impellers mounted on a single shaft. In some embodiments, the shaft is a stacked shaft, such that higher rotational speeds can be achieved due to the absence of the shrink fit connection.

[0014] The compressor according to the present disclosure includes a single shaft, on which several impellers are mounted. The impellers include at least two compressor impellers.

[0015] As defined herein, methanol synthesis gas, often referred to as syngas, is a mixture of gases that serves as the primary feedstock for the production of methanol. The composition of this gas is carefully controlled to optimize a methanol synthesis reaction, which combines hydrogen (H?), carbon monoxide (CO) and optionally carbon dioxide (CO?) to form methanol (CH3OH).

[0016] A system for compressing a working fluid comprises a rotary driver in rotary communication with a shaft of a compressor; where the compressor comprises a casing arrangement; and a first compressor section in the casing arrangement, the first compressor section comprising a multiple- stages with a rotating impeller running at a high speed; where at least one of the casing arrangement or the first compressor impeller comprises a material that is resistant to corrosion by carbon dioxide or hydrogen. The system may further comprise one or more additional compressor sections (a second compressor section and / or a third compressor section) arranged within the casing arrangement, where each additional compressor section comprises a separate compressor impeller mounted on the shaft. Each separate compressor impeller is mounted on the shaft such that each separate compressor impeller is separately supported and not integrally formed with another impeller and comprises a material that is resistant to corrosion by carbon dioxide or hydrogen. The shaft may be mounted on a magnetic bearing located in the casing arrangement and is devoid of a lubricant. The casing arrangement is also devoid of a gearbox. In an embodiment, the compressor is equipped with active magnetic bearings and is driven by a high-speed electric motor equipped with active magnetic71 PRO-511231 -W0-2_BHI0606PCT bearings. In an embodiment, the shaft is a stacked shaft, where rotary impeller outer diameter peripheral speeds are “high speed”, defined as 300 meters per second (m / s) or higher. In an embodiment, rotary impeller outer diameter peripheral speeds are in the range of 300 to 800 (m / s). In another embodiment, rotary impeller outer diameter peripheral speeds are in the range of 350 to 550 (m / s). in yet another embodiment, rotary impeller outer diameter peripheral speeds are in the range of 370-650 m / s. The speeds indicated in the various noted embodiments can be achieved because of the absence of a shrink fit connection.

[0017] In an embodiment, the first compressor section is operative to perform a first stage of compression on the working fluid and where the additional compressor sections (e.g., the second compressor section and / or the third compressor section) are operative to perform a second stage of compression and / or a third stage of compression respectively on the working fluid. Each succeeding stage of compression includes greater pressures than the preceding stage of compression.

[0018] With reference now to FIG. 1 , a system 100 for producing methanol comprises a natural gas 201 feed stream. The system 100 comprises a first charge gas compressor 101, a syngas purification and reformation system 400 that lies down stream of the charge gas compressor 101, a methanol synthesis system 500 that converts syngas (derived from the natural gas) into methanol and a methanol recycle system 600 that lies downstream of the methanol synthesis system 500.

[0019] The feed stream 201 comprises natural gas that is charged to a first charge gas compressor 101 where the pressure is increased for efficient steam reforming. In an embodiment, the natural gas comprises methane. The compressed natural gas is discharged via line 202 from the first charge gas compressor at pressures of 20 to 35 bar to the natural gas purification and reformation system 400. The natural gas purification and reformation system 400 comprises a desulfurization unit 101, a primary catalytic unit 103 and an oxygen blown secondary reformer 104 that lie in a series configuration with respect to each other. The desulfurization unit 10 land the oxygen blown secondary reformer 104 are in fluid communication with one another via the primary catalytic unit 103. The desulfurization unit 101 lies upstream of the primary catalytic unit 103, which lies upstream of the oxygen blown secondary reformer 104.

[0020] In the desulfurization unit 102, the sulfur compounds like hydrogen sulfide are removed using a catalyst, such as, for example, an amine-based catalyst. Examples of amine- based catalysts include monoethanolamine (MEA), diethanolamine (DEA),71 PRO-511231 -W0-2_BHI0606PCT methyldiethanolamine (MDEA), tertiary amine blends, diglycolamine (DGA), or a combination thereof.

[0021] Downstream of the desulfurization unit 102 is the primary catalytic unit 103. In the primary catalytic unit 103, steam 204 is added to stream 203 (which contains desulfurized natural gas) from the desulfurization unit 102, and the mixture of steam and desulfurized natural gas is passed over a catalyst to produce partially reformed syngas. Syngas is a mixture containing hydrogen, carbon monoxide and optionally carbon dioxide. The process of converting steam and natural gas into synthesis gas (syngas) is known as steam methane reforming (SMR). Catalysts used for steam methane reforming include nickel-based catalysts (e.g., nickel supported on alumina, silica, and so on), promoted nickel catalysts (e.g., promoters include alkali metals (e.g., potassium, calcium) or rare earth metals (e.g., cerium, lanthanum)), ruthenium catalysts, cobalt catalysts, platinum catalysts, ruthenium catalysts, or a combination thereof. The catalysts may be supported on cerium oxide, alumina, lanthanum oxide, or a combination thereof.

[0022] The partially reformed syngas (stream 205) (from the primary catalytic unit 103) along with oxygen (stream 206) are charged to the oxygen blown secondary reformer 104 where direct oxidation occurs. The oxygen blown secondary reformer 104 ensures complete conversion of the methane into hydrogen and carbon monoxide to provide fully reformed syngas 207. Downstream of the oxygen blown secondary reformer 104 are a series of heat exchangers. The first heat exchanger 105 and the second heat exchanger 107 are used to recover heat from the syngas 207 as the syngas 207 is cooled. The cooled syngas (see stream 210) is charged to the syngas purification and reformation system 400.

[0023] The syngas purification and reformation system 400 comprises a second compressor 108 in fluid communication with a methanol converter 109, with the methanol converter 109 lying downstream of the second compressor 108. The second compressor 108 is used to compress the syngas from stream 210 from 15 to 30 bar to a pressure of 50 to 100 bar. The compressed syngas is feed to the methanol converter 109. The second compressor 108 also receives a feed stream 215 (that comprises recycled syngas) from the methanol recycle system 600. The second compressor 108 thus receives a first stream of syngas 210 from the first compressor 101 and a second stream of recycled syngas 215 from the methanol recycle system 600. The second compressor 108 will be discussed in detail later in FIGs. 2 and 3.

[0024] The methanol converter 109 reacts the compressed syngas 211 with a catalyst under high temperature and pressure conditions to produce methanol. The conversion of71 PRO-511231 -W0-2_BHI0606PCT compressed syngas (a mixture of hydrogen (H2), carbon monoxide (CO), and carbon dioxide (CO2)) into methanol (CH3OH) is conducted through a methanol synthesis process. This catalytic process is performed under specific temperature and pressure conditions in the presence of a catalyst. Methanol synthesis from syngas occurs through the following key reactions - carbon monoxide hydrogenation, carbon dioxide hydrogenation and a side reaction (a water gas shift reaction). Catalysts used to convert syngas to methanol include copper (Cu) supported on zinc oxide (ZnO) and alumina (AI2O3). the zinc oxide and lumina function as promoters / supports. The temperature during the conversion of syngas to methanol is 200 to 300 °C, while the methanol convertor 109 pressure is 50 to 100 bar (5 to 10 MPa).

[0025] The methanol produced in the methanol synthesis system 500 is charged to a cooler 110 and then is charged downstream to the methanol recycle system 600 that lies downstream of the methanol synthesis system 500. The cooler 110 typically cools the produced methanol to a temperature where the methanol can be separated from unreacted syngas. In short, the cooler 110 typically cools the methanol received from the methanol synthesis system 500 (which is not pure and contain syngas and other reactants) to a temperature where the methanol and the unreacted syngas exists in two phases - a liquid phase that is rich in methanol and a gas phase that is rich in syngas and other unreacted gases.

[0026] The methanol recycle system 600 comprises a separator 111 that lies downstream of the cooler 110. It further comprises a storage tank 106 and a plurality of devolatilization chambers 113 and 116 that lie downstream of storage tank 106 and are in fluid communication with the storage tank 106. The methanol recycle system also includes heat exchanger 107, which receives a charge (shown via dotted line 216) from the separator 111 and supplies this feed (crude methanol) to heat exchanger 107.

[0027] The separator 111 receives methanol (which is not pure and contain syngas and other reactants) from the methanol synthesis system 500 and separates crude methanol stream (see stream 216) from recycled syngas (see stream 215) and purge gas (see stream 214). As noted above, the separation of crude methanol (liquid phase) from the gas phase (syngas and purged gas occurs) via phase separation. The separator 111 separates the condensed liquid (methanol-water mixture) from the gaseous phase (unreacted syngas). The gas (stream 214) exits from the top of the separator. The liquid is collected at the bottom (streams 215 and 216) for further processing.

[0028] Some of the recycled syngas and methanol 215 is charged back to the compressor 108. Most of the crude methanol 216 is charged through heat exchanger 107 to71 PRO-511231 -W0-2_BHI0606PCT tank 106 and pumped (via pump 112) to a series of devolatilization / distillation units via stream 217 that are included in the methanol recycle system 600.

[0029] The first devolatilization unit 113, and the second devolatilization unit 116 are used to remove volatile components, such as water and other impurities producing a methanol product 228. In the devolatilization unit 113, light end impurities with low boiling points are removed through the top of the unit. These are charged to a cooler 114 and then a separator 115. Vapor is purged via stream 220 and the liquid stream 221 is recycled back to the devolatilization unit 113. Heavy crude methanol (see stream 222) is charged to the second devolatilization unit 116. Lighter impurities with lower boiling points than methanol are removed through the top of the unit. These are charged to a cooler 117 and then a separator 118. Vapor is purged via stream 225 and the liquid (see stream 226) is recycled back to the devolatilization unit 116. Methanol (see stream 227) is pumped via pump 119 downstream (see stream 228) for further processing.

[0030] With reference now to FIG. 2, the second compressor 108 comprises a rotary driver 1200 in operative communication with a gearbox 1300 that drives the compressor 108. Compressor 108 will now be described in detail with reference to FIGS. 1, 2 and 3. In an embodiment, the rotary driver 1200 may be an electric motor, a steam turbine, a gas turbine, a water turbine, a wind turbine, a hydraulic motor, or a combination thereof. Rotary motion from the rotary driver 1200 is transmitted to the gearbox 1300 and the compressor 108 via one or more shafts 1400. For example, first shaft 1400A transmits rotary motion from the rotary driver 1200 to the gearbox 1300, while second shaft 1400B transmits rotary motion from the gearbox 1300 to the compressor 108.

[0031] The gearbox 1300 is optional and is located between an electric motor 1200 and the compressor 108 and is operative to modify the speed and torque to meet the operational needs of the compressor 108. The gearbox 1300 facilitates an alignment between the motor and compressor shafts and allows for flexibility in layout and design. It ensures that energy from the rotary driver 1200 is transmitted efficiently to the compressor 108, minimizing losses. Optimizing speed and torque ensures the compressor 108 operates within its optimal performance range, improving energy efficiency.

[0032] The second compressor 108 comprises a single casing that encompasses two or more compressor stages or three or more compressor stages. The multiple stages of a rotary compressor are mounted on the same shaft, the stages work together to progressively compress71 PRO-511231 -W0-2_BHI0606PCT the working fluid (e.g., syngas and / or methanol) by increasing its pressure and density at each stage. This arrangement is common in centrifugal, axial, and reciprocating compressors.

[0033] FIG. 3 is a schematic diagram that depicts an exemplary embodiment of the second compressor 108 with two compressor sections 1114A and 1114B, each of which comprises a single stage. With reference now to the FIG. 3, the second compressor 108 comprises an integral compressor configuration within a casing arrangement 1112. As used herein, the term “casing arrangement” refers to either a single casing that houses a rotating shaft or multiple interconnected compartments (each corresponding to a single compression stage) through which a rotating shaft extends. In an embodiment, the casing arrangement comprises separate casing compartments for each one of the first compressor section 1114A and second compressor section 1114B, the casing compartments being separated from one another by sealing arrangements along the shaft.

[0034] In the embodiment depicted in FIG. 3, the casing arrangement 1112 encloses the compressor sections. These compressor sections include a first compressor section (1114A) and a second compressor section (1114B). In an exemplary embodiment, both the first and second compressor sections (1114A and 1114B) may comprise a single stage with a single impeller. Each compressor section may include one or more stages of compression. For example, the first compressor section 1114A may perform a first stage of compression on the working fluid, while the second stage of compression may perform a second stage of compression on the same working fluid.

[0035] In another embodiment, each compressor section may perform more than one stage of compression on the working fluid. For example, a first compressor section may perform three sub-stages of compression on a working fluid - a first-first sub-stage, a first- second sub-stage and a first-third sub-stage before transporting the working fluid to a second compressor section, where additional compression stages may occur. Each sub-stage may be performed at a different operating temperature.

[0036] In an embodiment, the first compressor section and the second compressor section are arranged in an in-between bearing configuration (not shown), between the first bearing unit and the second bearing unit. In another embodiment, the first compressor section and the second compressor are arranged in series or alternatively are arranged in parallel. In yet another embodiment, an intercooler is arranged between the first compressor section and the second compressor section.71 PRO-511231 -W0-2_BHI0606PCT

[0037] Alternative embodiments may include a greater number of sections and / or configurations in which one, some, or all compressor sections feature multiple impellers. In an embodiment, intercoolers may be disposed between successive stages of the compressor.

[0038] Each stage comprises an inlet port and an outlet port. A two-stage compressor therefore contains two inlet ports and two outlet ports for the same working fluid, while a three- stage compressor contains three inlet ports and three outlet ports for the same working fluid. The number of inlet ports or the number of outlet ports is therefore the same as the number of stages in the compressor. The number of inlet ports is exclusive of ports that are used exclusively for injection of the recycle stream. The working fluid discharged from each stage serves as the input for the subsequent stage.

[0039] In an embodiment, each stage of compression is effected by a separate impeller (not shown) contained in a single casing 1112. Each stage takes the working fluid output from the previous stage (at higher pressure) and compresses it further. In other words, the second stage lies downstream of the first stage and a third stage lies downstream of the second stage. All stages are mounted on the same shaft, meaning the impellers or pistons are driven by the same power source and rotate or move in synchronization.

[0040] As may be seen in FIG. 3, the second compressor 108 comprises at least 3 inlet ports 1102, 1106 and 1108 and at least two outlet ports 1104 and 1110. First inlet port 1102 and first outlet port 1104 are the inlets and outlets for the first stage respectively, which receives the initial charge of the working fluid (e.g., syngas and / or methanol) at a first pressure Pl and compresses it to a second pressure P2 that is greater than Pl. In an embodiment, Pl is at atmospheric pressure. After undergoing compression to pressure P2, the syngas or methanol leaves the first stage of the compressor at first outlet port 1104 and re-enters the compressor at the second inlet port 1106, where it is subjected to additional pressurization in a second stage. The syngas or methanol at pressure P2 is transported to the second inlet port 1106 via steam 1116. In an embodiment, with reference to the FIG. 1, the first syngas stream 210 is charged to the first inlet port 1102. The first syngas stream is compressed in the first stage and exits at first outlet port 1104. It is then charged to port 1106 via stream 1116, where it is subjected to a second stage of compression to increase its pressure.

[0041] During the pressurization in the second stage, the recycle syngas stream 215 may be injected into the second stage via the third inlet port 1108. The gases (syngas and / or methanol) blended in will then exit the compressor 108 via the second outlet port 1110 at a pressure P3 (which is greater than P2).71 PRO-511231 -W0-2_BHI0606PCT

[0042] The casing arrangement 1112, therefore, includes an initial single compressor inlet port 1102 (into which the syngas and / or methanol is introduced at its lowest pressure) and a single final compressor outlet port 1110 (from which syngas and / or methanol is extracted at its highest pressure) with each of the successive stages located therebetween. Each stage is in fluid communication with a preceding stage or with a succeeding stage. The compressor stages 1114A and 1114B are arranged in series, i.e., in sequence, such that a same gas flow (e.g., syngas and / or methanol) is processed sequentially in the first stage 1114A and in the second stage 1114B.

[0043] In centrifugal or axial compressors, an impeller (centrifugal) or rotor blades (axial) accelerate the syngas and / or methanol, converting rotational energy into kinetic energy. In an embodiment, the syngas and / or methanol then passes through a diffuser or stator, where the kinetic energy is converted into pressure energy at pressure P2. In reciprocating compressors, the syngas and / or methanol is drawn into a cylinder, compressed by a piston, and discharged at a pressure P2 that is greater than Pl .

[0044] The output pressure from P2 from the first stage then becomes the input pressure for the second stage. In the second stage, the compression process is repeated, further increasing the pressure to a value of P3 where P3 is greater than P2. In centrifugal compressors, a smaller impeller or specifically designed blade geometry may be used to handle the denser fluid efficiently. In axial compressors, rotor and stator blade angles are adjusted in each stage to account for increasing fluid density. In reciprocating compressors, the fluid enters a smaller cylinder or is compressed by a piston with a shorter stroke to achieve further compression. The last stage delivers the compressed fluid at the desired pressure P3 for the specific application.

[0045] In an embodiment, the initial pressure Pl of the syngas and / or methanol lies between 0.5 to 35 bar, 1 to 5 bar for methanol produced via system 300, or 15 to 30 bar for methanol produced via the conventional system 100 while the final pressure Pn (where n is an integer that represents the nth stage (also referred to herein as the final stage)) is between 70 to 120 bar.

[0046] In another example, shown in FIG. 4, the system 300 is a green system used to produce methanol (see stream 228) through the use of hydrogen produced by an electrolyzer (301) and captured carbon dioxide (from a carbon dioxide storage 302). In an example, the electrolyzer 301 can be powered with electric energy from an electric power distribution grid (not shown). In some embodiments, the electric energy can at least partly be provided by one71 PRO-511231 -W0-2_BHI0606PCT or more renewable energy resources such as solar energy, wind, geothermal energy, wave and tidal energy, or the like can be used.

[0047] The carbon dioxide storage 302 may be captured carbon dioxide from industrial flue gases or directly through the air by the use of carbon dioxide absorption systems. Industrial processes where large-scale carbon dioxide capture occurs include coal gasification, ethanol production, fertilizer production, natural gas processing, refinery hydrogen production, and coal-fired power generation.

[0048] Hydrogen (from electrolyzer 301) and captured carbon dioxide (from carbon dioxide storage 302) are both separately maintained at pressures of 1 to 5 bar respectively. The hydrogen and carbon dioxide are mixed and charged via mixed stream 303 to the methanol synthesis system 500 (which (as detailed in FIG. 1), comprises the compressor 108 and the methanol converter 109). The first compressor 108 is used to compress the mixed stream 303 from a pressure of 1 to 5 bar to a pressure of 50 to 100 bar. The compressed syngas from the compressor 108 is charged to the methanol converter 109 via stream 211. From here, the remainder of the process is the same as detailed with respect to FIGS. 1, 2 and 3 for producing methanol and will not be repeated in the interests of brevity.

[0049] Set forth below are some embodiments of the foregoing disclosure:

[0050] Embodiment 1 : A system for compressing a working fluid includes a rotary driver in rotary communication with a shaft of a compressor; where the compressor comprises a casing arrangement; and a first compressor section in the casing arrangement, the first compressor section comprising a multiple-stages with a rotating impeller running at a high speed; where at least one of the casing arrangement or the first compressor impeller comprises a material that is resistant to corrosion by carbon dioxide or hydrogen and the compressor is operative to compress syngas to a pressure in the range of 50 to 120 bar.

[0051] Embodiment 2: The system of any prior embodiment , further comprising one or more additional compressor sections arranged within the casing arrangement, where each additional compressor section comprises a separate compressor impeller mounted on the shaft.

[0052] Embodiment 3: The system of any prior embodiment , where the shaft is mounted on magnetic bearings and wherein the system is devoid of a gearbox or where the compressor is equipped with active magnetic bearings and is driven by a high-speed motor equipped with active magnetic bearings, or alternatively, where the shaft is a stacked shaft, and where rotary impeller outer diameter peripheral speeds are in the range of 370 to 650 m / s, whichcan be achieved because of the absence of a shrink fit connection.71 PRO-511231 -W0-2_BHI0606PCT

[0053] Embodiment 4: The system as in any prior embodiment, where the casing arrangement is devoid of a lubricant.

[0054] Embodiment 5: The system as in any prior embodiment, where the rotary driver is at least one of an electric motor, a steam turbine, a gas turbine, a wind turbine, a hydraulic motor, a pneumatic motor, or a combination thereof.

[0055] Embodiment 6: The system as in any prior embodiment, where each separate compressor impeller is mounted on the shaft such that the each separate compressor impeller is separately supported and not integrally formed with another impeller and comprises a material that is resistant to corrosion by carbon dioxide or hydrogen.

[0056] Embodiment 7: The system as in any prior embodiment, where the first compressor section is operative to perform a first stage of compression on the working fluid and where the additional compressor sections are operative to perform a second stage of compression on the working fluid; where the second stage of compression includes greater pressures than the first stage of compression.

[0057] Embodiment 8: The system as in any prior embodiment, wherein the first compressor section and a second compressor section are arranged in an in-between bearing configuration, between a first bearing unit and a second bearing unit.

[0058] Embodiment 9: The system as in any prior embodiment, wherein the first compressor section and a second compressor are arranged in series.

[0059] Embodiment 10: The system as in any prior embodiment, wherein an intercooler is arranged between the first compressor section and a second compressor section.

[0060] Embodiment 11: The system as in any prior embodiment, wherein the first compressor section and a second compressor section are arranged in parallel.

[0061] Embodiment 12: The system as in any prior embodiment, wherein the shaft is sealingly housed in the casing arrangement.

[0062] Embodiment 13: The system as in any prior embodiment, wherein the casing arrangement comprises separate casing compartments for each one of the first compressor section and a second compressor section, the casing compartments being separated from one another by sealing arrangements along the shaft.

[0063] Embodiment 14: A method of pressurizing a working fluid, the method including transporting a working fluid comprising syngas and / or methanol to a compressor; where the compressor comprises a casing arrangement, and a first compressor section, the first compressor section comprising a multiple-stages with a rotating impeller running at a high71 PRO-511231 -W0-2_BHI0606PCT speed; where at least one of the casing arrangement or the first compressor impeller comprises a material that is resistant of corrosion by carbon dioxide or hydrogen, pressurizing the working fluid to a first pressure in the first compressor section, transporting the working fluid at the first pressure to the second compressor section; and pressurizing the working fluid to a second pressure in the second compressor section; where the second pressure is greater than the first pressure; and where the second pressure is operative to facilitate a reaction to convert syngas to methanol.

[0064] Embodiment 15: The method as in any prior embodiment, where the second pressure is 100 to 300 bar.

[0065] Embodiment 16: The method as in any prior embodiment, where the first pressure is 0.5 to 5 bar.

[0066] Embodiment 17: The method as in any prior embodiment, further comprising the second compressor section and a third compressor section where each of the second compressor section and the third compressor section comprising at least one compressor impeller mounted on the shaft for rotation therewith such that a second compressor impeller is separately supported and not integrally formed with a third compressor impeller.

[0067] Embodiment 18: A system as in any previous embodiment, where the system comprises a first charge gas compressor, a syngas purification and reformation system; that lies downstream of the charge gas compressor; a methanol synthesis system that converts the syngas into methanol; and a methanol recycle system that lies downstream of the methanol synthesis system; where the methanol synthesis system and the methanol recycle system he downstream of the syngas purification and reformation system; and where the methanol synthesis system comprises a second compressor and a methanol converter; where the second compressor comprises a rotary driver in rotary communication with a shaft of the second compressor; a casing arrangement; and a first compressor section in the casing arrangement, the first compressor section comprises a multiple-stages with a rotating impeller running at a high speed; where at least one of the casing arrangement or the first compressor impeller comprises a material that is resistant to corrosion by carbon dioxide or hydrogen.

[0068] Embodiment 19: A system as in any previous embodiment, wherein the methanol recycle system comprises a separator that separates gaseous product or byproduct from a liquid product.71 PRO-511231 -W0-2_BHI0606PCT

[0069] Embodiment 20: A system as in any previous embodiment, where a portion of the gaseous product or byproduct is charged to the second compressor and where a portion of the liquid product is charged to a plurality of devolatilization chamber.

[0070] The materials used in the components of the compressor sections such as, for example, impellers, blades, casings, pistons, shafts, and the like, are generally manufactured from materials that are resistant to corrosive action from hydrogen and carbon dioxide.

[0071] Materials used for protection against hydrogen corrosion include austenitic stainless steels (e.g., SS304, SS316, SS321, or a combination thereof, chromium-molybdenum (Cr-Mo) steels (e.g., 2*4 Cr-lMo, 9Cr-lMo. (or a combination thereof), nickel alloys (e.g., Inconel (nickel-chromium alloy), Monel (nickel-copper alloy), Hastelloy (nickel-molybdenum alloy), low carbon steels, cladded materials (e.g., base materials (e.g., carbon steel) are overlaid with a corrosion-resistant alloy such as stainless steel or Inconel), titanium alloys (grade 2 titanium), ferritic stainless steels (e.g., SS410, SS430, or a combination thereof), special high- strength alloys (Alloy 718 (nickel-chromium-iron- molybdenum), Alloy 625 (nickel- chromium-molybdenum), or a combination thereof.

[0072] The foregoing metals may be coated with chemically resistant polymers, such as, for example, polytetrafluoroethylene, polyolefins, polysiloxanes, or a combination thereof, when used in a compressor.

[0073] The materials used for protection against carbon dioxide or hydrogen attack include carbon steel, stainless steel (e.g., SS304, SS316, and the like), aluminum, nickel and nickel alloys (e.g., Monel (nickel-copper alloy), Inconel (nickel-chromium alloy), or a combination thereof. In an embodiment, these components (used to protect against carbon dioxide or hydrogen degradation) may be coated with chemically resistant polymers, such as, for example, polytetrafluoroethylene, polyolefins, polysiloxanes, or a combination thereof.

[0074] While the invention has been described in terms of various specific embodiments, it will be apparent to those of ordinary skill in the art that many modifications, changes, and omissions are possible without departing from the spirit and scope of the claims. In addition, unless specified otherwise herein, the order or sequence of any process or method stages may be varied or re-sequenced according to alternative embodiments. Specifically, in each of the configurations described above the two compressor sections can be arranged either in series or in parallel, unless differently specified. Also, the two compressors can be alternatively in series or in parallel, unless differently specified.

Claims

71 PRO-511231 -W0-2_BHI0606PCTCLAIMSWhat is claimed is:

1. A system for compressing a working fluid, the system characterized by: a rotary driver (1200) in rotary communication with a shaft of a compressor (108); where the compressor (108) comprises: a casing arrangement (1112); and a first compressor section (1114A) in the casing arrangement, the first compressor section (1114A) comprising a multiple-stages with a rotating impeller running at a high speed; where at least one of the casing arrangement or the first compressor impeller comprises a material that is resistant to corrosion by carbon dioxide or hydrogen; where the compressor is operative to compress syngas to a pressure of 50 to 120 bar.

2. The system of claim 1 , further comprising one or more additional compressor sections arranged within the casing arrangement, where each additional compressor section comprises a separate compressor impeller mounted on the shaft.

3. The system of claim 1, where the shaft is mounted on magnetic bearings and wherein the system is devoid of a gearbox or where the compressor is equipped with active magnetic bearings and is driven by a high-speed motor equipped with active magnetic bearings, or alternatively, where the shaft is a stacked shaft, and where rotary impeller outer diameter peripheral speeds are 370 to 650 m / s, which is achieved because of the absence of a shrink fit connection.

4. The system of claim 1, where the casing arrangement (1112) is devoid of a lubricant.

5. The system of claim 2, where each separate compressor impeller is mounted on the shaft such that the each separate compressor impeller is separately supported and not integrally formed with another impeller and comprises a material that is resistant to corrosion by carbon dioxide or hydrogen.

6. The system of claim 2, where the first compressor section is operative to perform a first stage of compression on the working fluid and where the additional compressor sections are operative to perform a second stage of compression on the working fluid; where the second stage of compression includes greater pressures than the first stage of compression.

7. The system of claim 2, wherein the first compressor section (1114A) and a second compressor section (1114B) from the one or more additional compressor sections are71 PRO-511231 -W0-2_BHI0606PCT arranged in an in-between bearing configuration, between a first bearing unit and a second bearing unit.

8. The system of claim 7, wherein an intercooler is arranged between the first compressor section (1114A) and a second compressor section (1114B).

9. The system of claim 1 , wherein the shaft is sealingly housed in the casing arrangement (1112).

10. The system of claim 7, wherein the casing arrangement (1112) comprises separate casing compartments for each one of the first compressor section (1114A) and a second compressor section (1114B), the casing compartments being separated from one another by sealing arrangements along the shaft.

11. A method of pressurizing a working fluid, the method characterized by: transporting a working fluid comprising syngas and / or methanol to a compressor; where the compressor comprises: a casing arrangement (1112); and a first compressor section (1114A), the first compressor section (1114A) comprising a multiple- stages with a rotating impeller running at a high speed; where at least one of the casing arrangement or the first compressor impeller comprises a material that is resistant of corrosion by carbon dioxide or hydrogen; pressurizing the working fluid to a first pressure in the first compressor section; transporting the working fluid at the first pressure to a second compressor section (1114B); and pressurizing the working fluid to a second pressure in the second compressor section (1114B); where the second pressure is greater than the first pressure; and where the second pressure is operative to facilitate a conversion of syngas to methanol.

12. The method of claim 11, where the second pressure is 100 to 300 bar.

13. The method of claim 11, where the first pressure is 0.5 to 5 bar.

14. The method of claim 11, further comprising the second compressor section(1114B) and a third compressor section where each of the second compressor section (1114B) and the third compressor section comprising at least one compressor impeller mounted on the shaft for rotation therewith such that a second compressor impeller is separately supported and not integrally formed with a third compressor impeller.

15. A system for compressing a working fluid, the system characterized by: a first charge gas compressor (101),71 PRO-511231 -W0-2_BHI0606PCT a syngas purification and reformation system (400); that lies downstream of the charge gas compressor (101); a methanol synthesis system (500) that converts the syngas into methanol; and a methanol recycle system (600) that lies downstream of the methanol synthesis system (500); where the methanol synthesis system (500) and the methanol recycle system (600) lie downstream of the syngas purification and reformation system (400); and where the methanol synthesis system (500) comprises a second compressor (108) and a methanol converter (109); where the second compressor (108) comprises: a rotary driver (1200) in rotary communication with a shaft of the second compressor (108); a casing arrangement (1112); and a first compressor section (1114A) in the casing arrangement (1112), the first compressor section (1114A) comprises a multiple- stages with a rotating impeller running at a high speed; where at least one of the casing arrangement or the first compressor impeller comprises a material that is resistant to corrosion by carbon dioxide or hydrogen.

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