Closed-Loop Methane Production with Produced-Water Gas Cleaning
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Solution Overview
Problem
Existing methane production systems face safety concerns due to methane dissolving in water, leading to environmental burdens when discharged water is released, and inefficiencies in utilizing produced water for impurity removal.
Innovation Solution
A methane production system with a closed loop design where produced water from the reaction tank is used to dissolve water-soluble impurities and replace dissolved methane with CO2, utilizing a spray nozzle and circulation system to enhance contact and separation efficiency.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If water is used to separate and remove components from reaction gas, then separation efficiency is improved, but methane dissolves in the water causing safety concerns and environmental burden
Solution Approach 1:
The patent extracts and removes methane from the water that was used for separation. The water containing dissolved methane is circulated back to the reaction tank where methane is stripped from the water by the reaction gas environment, and the liberated methane is recovered with the reaction gas. This extraction process eliminates the harmful effect of methane dissolution while preserving the beneficial separation function.
Solution Approach 2:
The patent introduces a circulation system as an intermediary mechanism between the separation process and methane recovery. The water acts as a carrier that temporarily holds methane during separation, then releases it in the reaction tank. This intermediary approach allows the system to achieve both efficient separation and methane recovery without direct harmful interaction.
2Device complexity
If produced water is discharged after separation, then the separation process is simplified, but safety concerns and environmental burden increase due to methane content
Solution Approach 1:
The patent implements a continuous circulation of water from the separation process back to the reaction tank. Instead of discharging water after single-use separation, the system continuously recycles water through the reaction tank where methane is continuously stripped, ensuring water is always free of dissolved methane when discharged. This continuous action maintains both safety and operational efficiency.
Solution Approach 2:
The reaction tank environment serves dual purposes: it not only performs the chemical reaction but also acts as a methane stripping zone for the circulating water. The reaction gas in the tank naturally strips methane from the water without requiring additional energy input or complex equipment, allowing the system to purify water for discharge using its own operational conditions.
3Reliability
If water is circulated to remove methane, then safety is improved, but energy consumption increases due to circulation requirements
Solution Approach 1:
The patent merges the methane stripping function with the existing reaction tank operation. The water circulation system utilizes the reaction tank's gas phase environment as a natural stripping zone, combining the chemical reaction process with the methane removal process. This integration eliminates the need for separate stripping equipment and reduces energy consumption compared to dedicated methane removal systems.
Solution Approach 2:
The reaction gas in the reaction tank serves as a self-powered stripping medium for removing methane from water. The natural concentration gradient and gas flow in the reaction tank automatically strip methane without requiring external energy input for heating or pressurization. The system uses its own operational conditions to perform the energy-intensive methane removal function.
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 improves safety by reducing methane discharge and environmental impact while efficiently utilizing produced water for impurity removal, ensuring stable operation and effective methane recovery.
Implementation Method 1
a cleaning tank upstream of the reaction tank and configure to remove water-soluble impurities by bringing the raw material gas into contact with water
Implementation Method 2
the methane dissolved in the produced water is replaced by CO2
Data Source
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Figure 2
AI summary
A methane production system comprises: a reaction tank that produces methane and water by reacting CO and/or CO2 supplied to the reaction tank with hydrogen; a cleaning tank that is located at an upstream side of the reaction tank in a supply direction of the CO and/or CO2, and removes water-soluble impurities from a raw material gas including the CO and/or CO2 and the water-soluble impurities by bringing the raw material gas into contact with water; and a first supply line that supplies the raw material gas from which the water-soluble impurities are removed from the cleaning tank to the reaction tank; and a second supply line supplies water produced in the reaction tank from the reaction tank to the cleaning tank to bring the produced water into contact with the raw material gas in the cleaning tank.