Waste CO2 Conversion to Fuels via Steam Methane Reformer
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Solution Overview
Problem
Current methods do not effectively utilize waste carbon dioxide to produce transport fuels, leading to ongoing carbon dioxide emissions and inefficiencies in fuel production processes.
Innovation Solution
A method involving the introduction of natural gas, steam, and recovered carbon dioxide to a reformer to produce synthesis gas, which is then processed through a water gas shift unit and a Fischer-Tropsch unit to produce fuel, while also generating carbon credits from reduced emissions.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If conventional fuel production methods are used, then fuel production efficiency is maintained at current levels, but carbon dioxide emissions continue to increase and waste CO2 is not utilized
Solution Approach 1:
The patent applies this principle by converting waste carbon dioxide emissions into a valuable feedstock for fuel production. The CO2 recovery unit captures emissions that would otherwise be harmful, and the subsequent conversion units transform this waste material into synthesis gas and ultimately liquid transport fuels, thereby converting an environmental liability into an economic and environmental asset
Solution Approach 2:
The patent implements this principle through the CO2 recovery unit that captures and recovers carbon dioxide from emission streams. Instead of discarding CO2 into the atmosphere, the system recovers it for reuse in the fuel synthesis process, creating a circular economy approach where waste material is recovered and repurposed
2Object-generated harmful factors
If waste carbon dioxide is recovered and converted into fuel, then carbon dioxide emissions are reduced and carbon credits are generated, but additional processing units and steps are required
Solution Approach 1:
The patent applies this principle by designing a integrated gas to liquids plant where existing processing units serve multiple functions. The reformer and conversion units process both traditional natural gas feedstock and recovered CO2 through the same equipment, allowing the system to handle multiple feedstocks and produce multiple product streams without requiring entirely separate processing lines
3Quantity of substance
If recovered carbon dioxide is introduced to the reformer, then synthesis gas is produced with reduced net emissions, but the reformer must process additional feedstock components
Solution Approach 1:
The patent applies this principle by adjusting operational parameters of the reformer to accommodate CO2 as a feedstock component. The system modifies temperature, pressure, and residence time parameters to optimize the reforming reaction when processing mixed feedstocks containing both natural gas and recovered CO2, thereby maintaining efficient synthesis gas production while handling variable feedstock composition
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 method increases fuel production efficiency, reduces carbon dioxide emissions, and generates carbon credits, offering a more sustainable and economically beneficial approach to fuel production.
Implementation Method 1
introducing natural gas, steam, and recovered carbon dioxide to a reformer to produce unshifted synthesis gas (syngas)
Implementation Method 2
introducing a portion of the unshifted syngas to a water gas shift unit to produce a shifted syngas
Implementation Method 3
introducing a portion of the unshifted syngas to a Fischer-Tropsch (FT) unit to produce an FT product
Data Source
AI summary
A method of producing fuel from CO2 comprising introducing natural gas, steam, and recovered CO2 to a reformer to produce unshifted syngas characterized by a molar ratio of hydrogen to carbon monoxide of from about 1.7:1 to about 2.5:1; introducing the unshifted syngas to a water gas shift unit to produce a shifted syngas, wherein an amount of CO2 in the shifted syngas is greater than in the unshifted syngas; separating the CO2 from the shifted syngas to produce recycle CO2 and a hydrogen-enriched syngas; recycling the recycle CO2 to the reformer; introducing the unshifted syngas to a Fischer-Tropsch (FT) unit to produce an FT product, FT water, and FT tail gas, wherein the FT product comprises FT liquids and FT wax; and separating the FT liquids from the FT product to produce a fuel.