Modular Ceramic Oxygen Membrane Reactor With Thermal Coupling
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Solution Overview
Problem
Existing oxygen transport membrane based reforming systems face challenges such as high operating temperatures leading to excessive carbon formation, complex and costly installations, and inefficient thermal coupling between oxygen transport membrane tubes and catalytic reforming tubes.
Innovation Solution
A commercially viable modular ceramic oxygen transport membrane assembly with improved thermal coupling, manufacturability, and maintainability, featuring a reactively driven oxygen transport membrane tube assembly that enhances the efficiency of synthesis gas production.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Temperature
If high temperatures (900-1100°C) are used in oxygen transport membrane based reforming systems, then the endothermic heating requirements for steam methane reforming are satisfied, but excessive carbon formation occurs in the hydrocarbon feed stream
Solution Approach 1:
The reactor is divided into multiple zones with different temperature profiles. The oxygen transport membrane tubes are arranged such that oxidation reactions occur at higher temperatures while reforming reactions occur at lower temperatures, preventing excessive carbon formation while still satisfying endothermic heating requirements
Solution Approach 2:
Different regions of the reactor are maintained at different temperatures and oxygen partial pressures. The hydrocarbon feed is introduced into regions with controlled oxygen availability and temperature to prevent carbon formation, while other regions maintain high temperatures for endothermic reactions
2Productivity
If conventional SMR or POx processes are used, then synthesis gas production is achieved, but significant carbon dioxide emissions are released to the atmosphere
Solution Approach 1:
Oxygen is transported through the oxygen transport membrane tubes and used for partial oxidation of hydrocarbons, providing concentrated oxygen supply that enables complete combustion and carbon capture while maintaining synthesis gas production efficiency
Solution Approach 2:
The system combines oxygen transport membrane technology with catalytic reforming, creating a composite process that integrates separation and reaction functions to achieve both synthesis gas production and carbon dioxide capture
3Object-generated harmful factors
If a separate air separation unit is added to produce high purity oxygen for ATR process, then carbon capture is facilitated, but system complexity and capital cost increase
Solution Approach 1:
The oxygen separation and reforming functions are merged into a single integrated reactor system. The oxygen transport membrane tubes perform both oxygen separation from air and delivery of oxygen to the hydrocarbon feed, eliminating the need for separate air separation units
Solution Approach 2:
The oxygen transport membrane tubes serve multiple functions simultaneously: they act as oxygen separation membranes, heat transfer surfaces, and reaction zones. This multi-functionality reduces overall system complexity while achieving carbon capture
4Ease of manufacture
If oxygen transport membrane tubes are arranged with poor thermal coupling, then manufacturing and maintenance become easier, but thermal integration efficiency decreases
Solution Approach 1:
The oxygen transport membrane tubes are nested within the reactor structure with catalytic reforming tubes positioned concentrically or adjacently. This nested arrangement maximizes thermal coupling between oxidation and reforming zones while maintaining modular construction for ease of manufacture
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 solution achieves higher thermal integration efficiency, increased heat transfer surface areas, and improved packing density, optimizing synthesis gas production while reducing costs and complexity.
Implementation Method 1
A typical oxygen transport membrane has a dense layer that, while being impervious to air or other oxygen containing gas, will transport oxygen ions when subjected to an elevated operational temperature and a difference in oxygen partial pressure across the membrane
Implementation Method 2
oxygen transport membrane to supply oxygen and thereby generate the heat necessary to support endothermic heating requirements of the steam methane reforming reactions
Implementation Method 3
endothermic heating requirements for steam methane reforming reactions occurring within the reformer tubes
Data Source
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AI summary
The invention relates to a commercially viable modular ceramic oxygen transport membrane reforming reactor configured using repeating assemblies of oxygen transport membrane tubes and catalytic reforming reactors.