Autothermal Reformer Integrated with Gas Turbine for CO2 Capture
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Solution Overview
Problem
Current processes for producing concentrated carbon dioxide and electricity from hydrocarbon feedstocks are inefficient and lack integration with combined cycle power plants, limiting the effectiveness of carbon dioxide displacement in hydrocarbon-bearing formations.
Innovation Solution
An integrated process using an air-blown autothermal reformer (ATR) within a combined cycle power plant, where an air and fuel feed stream are introduced to an ATR to produce synthesis gas, which is then heat exchanged and processed to generate steam and separate concentrated carbon dioxide, with the hydrogen stream combusted in a gas turbine to produce electricity, and superheated steam used to drive additional electricity generation or mechanical processes.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If an air-driven autothermal reformer is used to produce synthesis gas, then concentrated carbon dioxide can be obtained, but the process requires complex integration with combined cycle power plant systems
Solution Approach 1:
The patent combines the carbon dioxide production process with a combined cycle power plant into an integrated system. The air-driven autothermal reformer is merged with gas turbine units, steam turbines, and carbon dioxide separation units to simultaneously generate concentrated CO2 and electricity while utilizing waste heat recovery
Solution Approach 2:
The integrated system performs multiple functions: the air-driven reformer produces synthesis gas that is then processed to generate concentrated CO2 for injection, while the same system generates electricity through gas and steam turbines, and recovers heat for various process streams, making the system multi-functional
2Power
If synthesis gas is heat exchanged to produce steam, then additional electricity can be generated via steam turbine, but energy losses occur during heat exchange and steam generation
Solution Approach 1:
The patent converts waste heat from the synthesis gas stream, which would otherwise be lost, into useful steam for driving the steam turbine. The heat exchange process transforms thermal energy that would be discarded into mechanical work and additional electricity generation
Solution Approach 2:
The system utilizes temperature parameter changes in the synthesis gas stream during heat exchange to generate steam at different pressure levels, which then drives the steam turbine to produce additional electricity, optimizing energy utilization across different temperature ranges
3Power
If hydrogen stream is combusted in gas turbine, then electricity is produced, but nitrogen in the stream affects combustion efficiency and exhaust composition
Solution Approach 1:
The patent uses a carbon dioxide separation unit as an intermediary to remove nitrogen and other impurities from the synthesis gas before combustion. This purification step ensures that the hydrogen stream combusted in the gas turbine has optimal composition for efficient combustion and reduced exhaust emissions
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 process efficiently generates concentrated carbon dioxide and electricity while optimizing steam usage for enhanced power generation and mechanical processes, improving the displacement of hydrocarbons in hydrocarbon-bearing formations.
Implementation Method 1
introducing an air feed stream comprising air and optionally steam and a fuel feed stream comprising methane and optionally hydrogen and/or steam to an autothermal reactor unit (ATR) for the production of synthesis gas
Implementation Method 2
heat exchanging the synthesis gas stream with a water stream for the production of steam and subsequently heat exchanging the synthesis gas stream with at least one process stream selected from the group consisting of a hydrocarbon feedstock, a pre-reformer feed stream, the fuel feed stream, a hydrogen stream, boiler feed water, the air feed stream, and steam for the production of superheated steam
Implementation Method 3
passing at least a portion of the synthesis gas stream to a shift converter unit where the synthesis gas reacts with steam to generate additional carbon dioxide and hydrogen
Implementation Method 4
passing the shift converted gas stream to a carbon dioxide separation unit for the separation of a concentrated carbon dioxide stream from a hydrogen stream comprising hydrogen and nitrogen
Implementation Method 5
combusting at least part of the hydrogen stream in a gas turbine wherein the gas turbine drives an electric generator thereby producing electricity and wherein combustion of the hydrogen stream generates an exhaust gas
Implementation Method 6
any superheated steam generated in steps (b) and/or (d) may be supplied to a steam turbine that drives an electric generator thereby producing additional electricity
Data Source
Figure 1
AI summary
A process for the production of carbon dioxide in concentrated form and electricity from a hydrocarbon feedstock said process comprising the steps of: a) introducing an air feed stream comprising air and optionally steam and a fuel feed stream comprising methane and optionally hydrogen and/or steam to an autothermal reactor unit (ATR) for the production of synthesis gas wherein (i) the temperature of the fuel feed stream is in the range 350 to 7000C; and (ii) the molar ratio of oxygen contained in the air feed stream to carbon (in hydrocarbons) in the fuel feed stream is from 0.45:1 to 0.85:1, preferably 0.6:1 to 0.7:1; b) withdrawing a synthesis gas stream comprising methane, hydrogen, carbon monoxide, carbon dioxide, nitrogen and optionally steam from the ATR and heat exchanging the synthesis gas stream with a water stream for the production of steam and subsequently heat exchanging the synthesis gas stream with at least one process stream selected from the group consisting of a hydrocarbon feedstock, a pre-reformer feed stream, the fuel feed stream, a hydrogen stream, boiler feed water, the air feed stream, and steam for the production of superheated steam; c) if necessary, introducing steam to the synthesis gas stream before passing at least a portion of the synthesis gas stream to a shift converter unit where the synthesis gas reacts with steam to generate additional carbon dioxide and hydrogen; d) withdrawing a shift converted gas stream from the shift converter unit and heat exchanging the shift converted gas stream with at least one process stream selected from the group consisting of a hydrocarbon feedstock, a pre-reformer feed stream, the fuel feed stream, a hydrogen stream, boiler feed water, the air feed stream, water for the production of steam, and steam for the production of superheated steam; e) passing the shift converted gas stream to a carbon dioxide separation unit for the separation of a concentrated carbon dioxide stream from a hydrogen stream comprising hydrogen and nitrogen; f) combusting at least part of the hydrogen stream in a gas turbine wherein the gas turbine drives an electric generator thereby producing electricity and wherein combustion of the hydrogen stream generates an exhaust gas.