Attenuated Combustion Staging for Hydrogen and CO2 Capture

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Solution Overview

Problem

Existing fossil fuel-burning power plants release carbon emissions directly into the atmosphere, and previous carbon capture and sequestration (CCS) methods are economically inefficient and reduce power generation efficiency.

Innovation Solution

A method involving partial combustion of hydrocarbon fuel to produce a combustion gas stream containing hydrogen and carbon monoxide, followed by complete combustion of carbon monoxide to generate a carbon dioxide working fluid, which is then used to produce clean energy, with optional hydrogen capture and carbon sequestration.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Power

If full combustion of hydrocarbon fuel is used to generate power, then power generation efficiency is improved, but carbon emissions are released directly into the atmosphere and hydrogen is not captured

Engineering Contradiction:

Improvepower generation efficiencyVSAvoidcarbon emissions

Core Design Contradiction:

PowerVSObject-generated harmful factors

Solution Approach 1:

The combustion process is segmented into two distinct stages: (1) partial combustion of hydrocarbon fuel to produce hydrogen and carbon monoxide, and (2) complete combustion of carbon monoxide to produce carbon dioxide. This segmentation allows selective capture of hydrogen while maintaining power generation, resolving the contradiction between efficient power generation and carbon emission reduction.

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

Hydrogen is extracted from the combustion products during the partial combustion stage and captured separately from the carbon dioxide stream. This extraction enables the valuable hydrogen resource to be recovered and utilized, while the remaining carbon dioxide can be captured and sequestered, addressing both power generation and emission reduction goals.

Inventive Principle:

Principle #2Taking out (Extraction)

2Object-generated harmful factors

If carbon capture and sequestration equipment is added to existing power plants, then carbon emissions are captured, but power generation efficiency is reduced and costs increase

Engineering Contradiction:

Improvecarbon captureVSAvoidpower generation efficiency

Core Design Contradiction:

Object-generated harmful factorsVSPower

Solution Approach 1:

The carbon capture function is merged with the existing combustion process by utilizing the carbon monoxide combustion stage to produce carbon dioxide for capture. This integration eliminates the need for separate, efficiency-reducing CCS equipment while maintaining carbon capture capability, thus resolving the contradiction between emission reduction and power generation efficiency.

Inventive Principle:

Principle #5Merging (Combining)

Solution Approach 2:

The combustion system performs multiple functions simultaneously: (1) generates power through controlled combustion, (2) produces hydrogen as a valuable byproduct, and (3) generates carbon dioxide for capture and sequestration. This multi-functionality eliminates the need for additional dedicated CCS equipment, maintaining power generation efficiency while achieving carbon capture.

Inventive Principle:

Principle #6Universality (Multi-functionality)

3Power

If stoichiometric oxygen is used to oxidize hydrocarbon to carbon dioxide and water, then complete combustion is achieved, but hydrogen is not intentionally generated and captured

Engineering Contradiction:

Improvecombustion efficiencyVSAvoidhydrogen loss

Core Design Contradiction:

PowerVSObject-generated harmful factors

Solution Approach 1:

Instead of using stoichiometric oxygen to completely oxidize hydrocarbon to carbon dioxide and water, the process inverts the approach by using limited oxygen to produce hydrogen and carbon monoxide as primary products. This inversion allows hydrogen to be captured as a valuable resource while the carbon content is later oxidized to carbon dioxide for capture, resolving the contradiction between combustion efficiency and hydrogen recovery.

Inventive Principle:

Principle #13The other way round (Inversion)

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 reduces oxygen consumption by 40%, lowers costs, and generates more hydrogen than electricity, achieving a thermal efficiency of 50-70% with minimal CO2 emissions, enabling efficient carbon capture and hydrogen production.

Implementation Method 1

partially combusting a hydrocarbon fuel and providing a combustion gas stream, the combustion gas stream comprising hydrogen and carbon monoxide (CO)

Methodology Applied

Scientific EffectPartial combustion: Combustion

Implementation Method 2

completely combusting at least a portion of the CO and providing a source of carbon dioxide (CO2) working fluid

Methodology Applied

Scientific EffectComplete combustion: Combustion

Data Source

PatentUS20250290444A1Attenuated combustion for clean power and hydrogen capture

Publication Date: 2025.09.18 NUCOR CORP

AI summary

Systems and systems to generate clean energy and for providing hydrogen capture and carbon capture sequestration are provided. Hydrogen from partial combustion of hydrocarbon fuel in combination with full combustion of carbon from hydrocarbon fuel is used to generate clean power with hydrogen capture and carbon capture sequestration.