Biomass-to-Methanol Catalysis Under Fluctuating Power Supply
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Solution Overview
Problem
Existing methods for producing methanol from biomass are not energy-efficient and do not account for fluctuating electricity supply, leading to inefficiencies and potential safety hazards due to intermittent renewable energy sources.
Innovation Solution
A process involving electrolysis to produce O₂ and H₂, followed by catalytic conversion of biomass to formic acid, then to methyl formate, and finally to methanol, with a buffer system to adjust hydrogenation based on electricity availability, using a polyoxometalate catalyst and optional additional catalysts for esterification and hydrogenation, ensuring continuous operation and safety.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If a full-load synthesis plant operates continuously to maximize production, then productivity increases, but energy efficiency decreases due to operation during low-renewable-energy periods
Solution Approach 1:
The plant operates dynamically by adjusting its operational status between full-load operation, partial-load operation, and shutdown based on real-time renewable energy availability. This dynamic operation allows the plant to capture high-value renewable energy periods for intensive production while reducing operation during low-renewable periods, resolving the contradiction between maintaining high productivity and energy efficiency.
Solution Approach 2:
The invention changes the operational parameters (production rate, electricity consumption) based on the parameter of renewable energy availability. By varying these parameters according to external conditions, the plant achieves both high annual productivity and high energy efficiency, as it produces maximum output during high-renewable periods and minimizes production during low-renewable periods.
2Use of energy by moving object
If the plant operates only during renewable energy surplus periods to improve energy efficiency, then energy efficiency increases, but productivity decreases due to intermittent operation
Solution Approach 1:
The plant performs preliminary actions by building up product inventories during high-renewable-energy periods before shutdown or reduced operation. This allows the plant to maintain high energy efficiency by operating only during favorable periods while still achieving high annual productivity through the accumulated production during intensive operation phases.
Solution Approach 2:
The invention maintains continuity of useful action through a buffer storage system that decouples the production process from continuous operation. The buffer allows the plant to operate intermittently based on energy availability while maintaining continuous product availability, thus preserving both energy efficiency and annual productivity.
3Adaptability or versatility
If the plant operates during start-up processes frequently to adapt to fluctuating electricity supply, then adaptability increases, but catalyst aging accelerates reducing reliability
Solution Approach 1:
The plant employs periodic action by operating in distinct phases: intensive full-load operation during high-renewable periods followed by shutdown or reduced operation during low-renewable periods. This periodic pattern reduces the frequency of start-up processes compared to continuous adaptation, thereby protecting catalyst lifespan while maintaining adaptability through planned operational cycles.
Solution Approach 2:
The dynamic operation strategy allows the plant to adapt to electricity fluctuations by adjusting operational intensity rather than frequency. By operating at high intensity during favorable periods and reducing operation during unfavorable periods, the plant achieves adaptability without subjecting catalysts to repeated thermal and mechanical stress from frequent start-ups.
4Productivity
If high pressure is used for catalyst oxidation to improve reaction efficiency, then reaction rate increases, but safety hazards increase
Solution Approach 1:
The invention replaces the mechanical approach of using high pressure to drive catalyst oxidation with a chemical approach using oxygen-enriched atmosphere at reduced pressure. This substitution maintains high oxidation reaction rates through enhanced oxygen availability while eliminating the safety hazards associated with high-pressure operations.
Solution Approach 2:
The invention uses oxygen-enriched air (high oxygen concentration) to accelerate catalyst oxidation without requiring high pressure. The increased oxygen partial pressure in the enriched atmosphere drives the oxidation reaction efficiently at atmospheric or reduced pressure, achieving both high reaction rate and improved safety.
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
The process achieves high energy efficiency, safety, and economic viability by adapting to fluctuating electricity supply, allowing continuous biomass conversion and reducing catalyst oxidation pressure, thus minimizing costs and hazards.
Implementation Method 1
O2 and H2 are produced from water by electrolysis using electric current
Implementation Method 2
the biomass is converted to formic acid in a first reaction vessel using an aqueous solution of a first catalyst
Implementation Method 3
The first catalyst, reduced in the catalytic reaction, is returned to its initial state by oxidation. To oxidize the reduced catalyst, the O2 produced in the first stage is introduced into the solution in the first reaction vessel
Implementation Method 4
the formic acid is converted to methyl formate in a second reaction vessel using an acidic second catalyst, in particular a solid acidic catalyst
Implementation Method 5
The methyl formate is then converted to MeOH by hydrogenolysis using hydrogen from water electrolysis. Cu0,9Al2O4 spinel materials are proposed as catalysts for the hydrogenolysis
Data Source
Figure 1
AI summary
The invention relates to a process for the catalytic production of methanol from biomass using electric current, wherein in a first stage O2 and H2 are produced from water by electrolysis, wherein in a second stage the biomass is converted to formic acid in a first reaction vessel (R1) using an aqueous solution of a first catalyst, wherein the first catalyst, reduced in the catalytic reaction, is returned to its initial state by oxidation, wherein the oxygen produced in the first stage is introduced into the solution in the first reaction vessel (R1) for its oxidation, wherein the solution with the formic acid produced therein is transferred to a second reaction vessel (R2), wherein methanol is added to the solution during the transfer to the second reaction vessel or in the second reaction vessel (R2), wherein the second reaction vessel (R2) is designed as a rectification column.in which optionally an acidic second catalyst is included, catalyzing the esterification of methanol with formic acid, wherein the second catalyst is present in solid form as a packed bed or in liquid form as an acid, wherein a reactive distillation is carried out in the second reaction vessel (R2) and the resulting methyl formate is transferred to a tank (T), wherein in a third stage the methyl formate is evaporated from the tank (T) and transferred to a third reaction vessel (R3) and there hydrogenated with the H2 from the first stage by means of a third catalyst catalyzing hydrogenation, whereby vaporous methanol is produced by hydrogenolysis, which is then removed from the third reaction vessel (R3) and cooled to such an extent that the methanol condenses.