Carbon Closed-Loop Fuel Process for Lower-Emission Aviation Fuel
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Solution Overview
Problem
The aviation industry's significant contribution to global greenhouse gas emissions, coupled with the heavy reliance on fossil fuels, necessitates the development of sustainable alternatives to reduce carbon footprints and comply with environmental regulations.
Innovation Solution
A carbon closed-loop system that integrates direct flue gas electrolysis for green hydrogen production, carbon dioxide capture using novel sorbent materials, and low-temperature methanation to produce green methane, which can replace conventional fossil fuels in industrial furnaces and boilers, thereby reducing emissions.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Object-affected harmful factors
If conventional fossil fuels are used in industrial furnaces, then energy supply is stable and combustion is efficient, but greenhouse gas emissions are high
Solution Approach 1:
The patent changes the chemical composition parameters of the fuel by producing green methane through carbonation of CO2 with green hydrogen, creating a fuel mixture with different combustion characteristics that reduces emissions while maintaining energy content
Solution Approach 2:
The patent converts harmful CO2 emissions from the furnace into useful green methane fuel through carbonation, transforming the waste product into a valuable energy carrier that can be combusted to generate power and reduce emissions
2Productivity
If water vapor is captured from flue gas for electrolysis, then green hydrogen production is enabled, but water vapor concentration in flue gas is low
Solution Approach 1:
The patent changes the physical state and concentration parameters of water by condensing water vapor from the flue gas stream, thereby increasing the water availability for electrolysis while maintaining the original flue gas composition
Solution Approach 2:
The patent introduces an intermediary condensation process that selectively removes water vapor from the flue gas, serving as a mediator between the low-concentration water vapor and the electrolysis process that requires higher water availability
3Measurement precision
If carbon dioxide is captured using sorbent materials, then CO2 removal efficiency is improved, but sorbent material regeneration requires additional energy
Solution Approach 1:
The patent implements a feedback mechanism where the CO2 captured by the sorbent is immediately carbonated with green hydrogen to produce green methane, creating a continuous feedback loop that maintains high CO2 removal efficiency while the produced methane provides energy that can be used for sorbent regeneration
Solution Approach 2:
The patent converts the energy-intensive sorbent regeneration process into a beneficial cycle by using the captured CO2 to produce green methane, which then provides the energy needed for regeneration, transforming the energy consumption into a self-sustaining process
4Object-affected harmful factors
If green methane is produced from CO2 and green hydrogen, then greenhouse gas emissions are reduced, but the process requires multiple energy-intensive steps
Solution Approach 1:
The patent merges multiple energy-intensive steps into an integrated process where CO2 capture, hydrogen production, and methanation are combined in a single system, allowing heat and energy to be exchanged between the different units, thereby reducing total energy consumption while maintaining emission reduction benefits
Solution Approach 2:
The patent converts the energy consumption of the methanation process into a benefit by producing green methane that can be combusted to generate power, creating a net energy-positive system where the energy input for process operations is offset by the energy recovery from fuel production
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 system achieves substantial reductions in greenhouse gas emissions, enhances combustion efficiency, and provides a pathway for Lower Carbon Aviation Fuel (LCAF) production, aligning with sustainability criteria and reducing reliance on conventional fuels.
Implementation Method 1
capturing, in a direct flue gas electrolysis (DFGE) unit, a water vapor from a flue gas from a furnace used in the industrial operation to produce green hydrogen and oxygen
Implementation Method 2
capturing, in a carbon removal unit, carbon dioxide from the flue gas
Implementation Method 3
feeding the carbon dioxide and the green hydrogen to a hydrogenation unit, wherein the hydrogenation unit includes a methanation process to produce green methane from the carbon dioxide and the green hydrogen
Implementation Method 4
utilizing the green methane and the oxygen in the furnace to enhance combustion efficiency and reduce greenhouse gas emissions
Data Source
AI summary
A carbon closed-loop system and process are provided. The carbon closed-loop system and process can be utilized in an industrial operation for producing, for example, a Lower Carbon Aviation Fuel (LCAF). The LCAF is produced by decarbonizing, for example, industrial furnaces and boilers, such as fired heaters, through the carbon closed-loop system and process which integrates renewable energy-driven H2 generation, CO2 capture, and methanation technologies to substantially reduce the carbon footprint of the industrial operation.