Aromatics Production with CO2 Conversion to Ethanol
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Solution Overview
Problem
Current aromatic complexes in the petrochemical industry are unable to produce biobased aromatics and co-produce ethanol, and they fail to effectively upgrade carbon in the form of CO and CO2 into high-value compounds.
Innovation Solution
Incorporating a reverse water gas shift (RWGS) unit to convert CO2 into CO, followed by a fermentation unit to produce ethanol, while recycling CO2 and utilizing existing catalytic units for aromatics production, allowing for the conversion of all carbon in the feedstock into aromatics and ethanol.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If pyrolysis is used to produce aromatic compounds, then aromatic production is achieved, but CO and CO2 by-products are generated that are not upgraded
Solution Approach 1:
The patent converts the harmful CO and CO2 by-products from pyrolysis into valuable ethanol through a two-step process: first, CO2 is converted to CO via reverse water-gas shift reaction, then both CO and remaining CO2 are fermented into ethanol by microorganisms. This transforms waste carbon into a high-value product, resolving the contradiction between maintaining high aromatics productivity and preventing carbon loss.
Solution Approach 2:
The patent changes the chemical state and form of carbon through sequential reactions: CO2 is converted to CO (change in oxidation state and molecular form), then both gases are converted to liquid ethanol through fermentation. These parameter changes enable the transformation of gaseous by-products into a liquid fuel product, achieving carbon upgrading while maintaining aromatics production.
2Productivity
If conventional aromatic complex processes are used, then aromatics are produced, but biobased carbon cannot be upgraded and ethanol cannot be co-produced
Solution Approach 1:
The patent adds multi-functionality to the aromatic complex by integrating a reverse water-gas shift unit and a fermentation unit. The pyrolysis unit now serves dual purposes: producing aromatics for the existing complex and generating CO/CO2 feedstock for ethanol production. This universal approach enables the same facility to simultaneously produce conventional aromatics, biobased aromatics, and ethanol, resolving the contradiction between productivity and adaptability.
Solution Approach 2:
The patent introduces intermediate processing units (reverse water-gas shift unit and fermentation unit) that act as mediators between pyrolysis and final products. These intermediaries convert CO2 to CO, then convert both gases to ethanol, enabling the complex to handle biobased feedstocks and produce multiple products without disrupting existing aromatics production capabilities.
3Device complexity
If CO and CO2 are not converted, then process simplicity is maintained, but carbon upgrading and ethanol co-production are lost
Solution Approach 1:
Rather than simply disposing of CO and CO2 or burning them for energy, the patent converts these by-products into valuable ethanol through chemical transformation. The reverse water-gas shift unit and fermentation unit add complexity but transform waste into wealth, achieving carbon upgrading and ethanol co-production while maintaining overall process efficiency.
Solution Approach 2:
The patent ensures continuous utilization of carbon throughout the process. CO2 from pyrolysis continuously feeds the reverse water-gas shift unit, which continuously produces CO for fermentation, which continuously generates ethanol. This continuous conversion eliminates carbon loss and maintains productive action throughout the entire system, justifying the added complexity through sustained value creation.
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
This approach enables the complete conversion of CO and CO2 by-products into ethanol, co-producing aromatics and upgrading biobased carbon, thereby overcoming the limitations of existing technologies.
Implementation Method 1
Incorporating a reverse water gas shift (RWGS) unit to convert CO2 into CO
Implementation Method 2
followed by a fermentation unit to produce ethanol
Implementation Method 3
Processes for the pyrolysis of hydrocarbon compounds produce aromatic compounds
Data Source
AI summary
Device and process for the conversion of a feedstock of aromatic compounds, in which the feedstock is treated notably by means of a fractionation train (4-7), a xylene separation unit (10) and an isomerization unit (11), and in which a pyrolysis unit (13) treats a second hydrocarbon feedstock, produces a pyrolysis effluent feeding the feedstock, and produces a pyrolysis gas comprising CO, CO2 and H2; a reverse water gas shift RWGS reaction section (50) treats the pyrolysis gas and produces an RWGS gas enriched in CO and in water; a fermentation reaction section (52) treats the RWGS gas enriched in CO and in water, and produces ethanol.