CO Shift Catalyst Temperature Control via Dynamic Gas Flow
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Solution Overview
Problem
The CO shift reaction apparatus faces challenges in maintaining the CO shift catalyst within a predetermined temperature range due to variations in gas flow rate and composition, leading to catalyst deterioration and inefficient gas refinement.
Innovation Solution
The apparatus includes multiple reactors with varying CO shift catalyst layer lengths and gas flow rate control units to adjust gas supply and separation, ensuring the catalyst operates within the optimal temperature range despite variations in gas flow and composition.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If the CO shift reaction is allowed to proceed while the CO shift catalyst is in the predetermined temperature range, then the CO shift reaction efficiency is improved, but the device complexity increases due to the need for multiple reactors and coolers
Solution Approach 1:
The patent makes the gas supply amount adjustable and dynamic through gas flow rate control units. The gas supply to each reactor can be flexibly changed based on gas flow rate and composition variations, allowing the system to maintain catalyst temperature within the optimal range without requiring multiple reactors and coolers. This dynamic adjustment capability resolves the contradiction by achieving efficient CO shift reaction while simplifying the device structure.
Solution Approach 2:
The patent changes the parameter of gas supply amount to control the reaction conditions. By adjusting the gas flow rate and composition parameters, the system can maintain the catalyst temperature within the predetermined range while optimizing the CO shift reaction efficiency. This parameter change approach allows single-reactor operation to achieve the same effect as multiple reactors, thereby reducing device complexity.
2Ease of manufacture
If the cooler size is determined based on the original design gas flow rate, then the manufacturing cost is controlled, but the reliability decreases when gas flow rate and composition vary significantly from design conditions
Solution Approach 1:
The patent introduces feedback control through gas flow rate control units that monitor and adjust the gas supply amount based on actual gas flow rate and composition. This feedback mechanism ensures the catalyst temperature remains within the optimal range even when operating conditions deviate from the original design, thereby maintaining high reliability without requiring an oversized cooler.
3Duration of action of stationary object
If multiple reactors and coolers are used to maintain catalyst temperature, then the catalyst lifespan is extended, but the device complexity and manufacturing cost increase
Solution Approach 1:
By making the gas supply amount dynamically adjustable through gas flow rate control units, the system can maintain catalyst temperature within the optimal range for extended periods, thereby extending catalyst lifespan. This dynamic control approach achieves the same protective effect as multiple reactors and coolers but with simpler and less expensive equipment.
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 configuration efficiently produces reformed gas while extending the lifespan of the CO shift catalyst, allowing for stable and flexible operation of the gas refining process.
Implementation Method 1
a CO shift reaction in which carbon monoxide (CO) reacts with water to produce hydrogen (H2) and carbon dioxide (CO2) is applied
Implementation Method 2
a CO shift catalyst which accelerates the reaction in which CO contained in the gasification gas is reformed and converted into CO2
Implementation Method 3
since the CO shift reaction is an exothermic reaction, the gasification gas is heated by the CO shift reaction in the CO shift reaction apparatus and thus the CO shift catalyst is heated
Data Source
AI summary
A CO shift reaction apparatus 11 according to the present invention includes: adiabatic reactors 31A to 31C, each having CO shift catalyst layers 35A to 35C filled with a CO shift catalyst 34 which reforms CO in gasification gas 15; gas supply lines l11 to l15 which supply the gasification gas 15 to the adiabatic reactors 31A to 31C; first gas flow rate control units 32A and 32B which adjust the amounts of gas supplied to the adiabatic reactors 31A to 31C; gas discharge lines l21 to l25 which discharge processing gas; and second gas flow rate control unit 33A and 33B which adjust flow rates of processing gas 38A-1, 38A-2, 38B-1, and 38B-2.