CO2 Hydrogenation Reactor with Syngas Recirculation
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Solution Overview
Problem
Current technologies for producing methanol and synthetic methane face challenges in managing intermittency of renewable energy, achieving stable production, and efficiently storing excess reagents, with existing systems requiring multi-stage operations, high pressure, and risking catalyst degradation due to temperature peaks.
Innovation Solution
A device and process for cogenerating methanol and synthetic methane using a CO2 hydrogenation reactor with recirculation systems to control flow rates and maintain isothermality, allowing flexible operation and efficient conversion of excess electrical energy into chemical products, with recirculation pipes and sensors to regulate temperature and flow rates, enabling constant production rates and storage of excess syngas as synthetic methane.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If multi-stage reactor operations with intermediate cooling are used to achieve high conversion rates, then conversion efficiency is improved, but device complexity and operating cost increase
Solution Approach 1:
The patent divides the catalytic bed into multiple zones with different catalyst types or activities arranged in sequence. This segmentation allows each zone to perform a specific function (e.g., primary conversion, secondary conversion, temperature control) within a single reactor, achieving high overall conversion without requiring multiple separate reactor stages and intermediate cooling systems.
Solution Approach 2:
The patent employs dynamic control mechanisms such as adjustable syngas flow rates, variable heating zones, or movable catalyst beds that can adapt to changing operating conditions. This dynamic capability allows the single reactor to maintain optimal conversion efficiency across different production rates without requiring complex multi-stage configurations.
2Productivity
If high pressure operation is used to favor methanol production, then conversion efficiency is improved, but operating cost and safety requirements increase
Solution Approach 1:
The patent optimizes the pressure parameter by operating at moderate pressures (e.g., 5-50 bar) rather than traditional high pressures. This is achieved by compensating for the reduced pressure effect through other means such as optimized catalyst selection, adjusted temperature profiles, or modified reactor configuration, thereby maintaining good conversion efficiency while significantly reducing operating costs and safety requirements.
Solution Approach 2:
The patent uses composite catalyst materials or reactor structures that enhance reaction efficiency at lower pressures. For example, novel catalyst compositions with higher activity or reactor designs with improved heat and mass transfer characteristics allow the system to achieve high methanol production rates without requiring high pressure operation.
3Reliability
If temperature control measures are implemented to prevent catalyst degradation, then catalyst lifetime is improved, but device complexity and energy consumption increase
Solution Approach 1:
The patent designs the reactor to utilize the reaction heat itself for temperature control. The exothermic methanol synthesis reaction generates heat that is automatically distributed throughout the catalytic bed through the reactor design (e.g., specific bed geometry, heat conduction pathways), preventing localized hot spots and catalyst degradation without requiring external cooling systems or complex temperature control mechanisms.
Solution Approach 2:
The patent maintains continuous optimal temperature conditions for catalyst performance by designing the reactor to sustain steady-state operation with uniform heat distribution. This continuous thermal management approach, achieved through optimized reactor geometry or catalyst bed configuration, prevents temperature fluctuations that could degrade catalysts while avoiding the need for intermittent cooling or complex control systems.
4Stability of the object's composition
If recirculation systems are used to manage excess syngas and maintain stable production, then production stability is improved, but device complexity increases
Solution Approach 1:
The patent combines the recirculation function with the main reactor system by integrating the unreacted syngas loop back into the reactor inlet or by merging multiple reactor outlets into a common recirculation line. This integration allows stable production to be maintained while minimizing the number of separate recirculation devices and reducing overall system complexity.
Solution Approach 2:
The patent designs components to serve multiple functions: the reactor vessel simultaneously performs conversion, temperature control, and recirculation; the catalyst bed provides both primary and secondary conversion zones; heat exchangers serve both cooling and preheating functions. This multi-functionality reduces the number of dedicated recirculation components needed while maintaining production stability.
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 provides flexible operation to match renewable energy availability, ensures stable methanol production, and stores excess energy as synthetic methane, enhancing the value of methanol production and reducing greenhouse gas emissions, while avoiding costly separations and maintaining reactor stability.
Implementation Method 1
CO2 hydrogenation reactor to produce methanol
Implementation Method 2
hydrogenation reaction... catalysts whose existing formulations are very diverse and widely available on the market
Implementation Method 3
a condenser, hydrogenation reaction products leaving the reactor, to separate at least the methanol and the water from the syngas in excess
Implementation Method 4
recirculation pipes and sensors to regulate temperature and flow rates... a heat exchanger whose outlet temperature is determined as a function of the sensed reaction temperature
Implementation Method 5
a methanation reactor comprising: an entry for part of the hydrogenation products comprising at least excess syngas following the hydrogenation reaction and an outlet for methanation reaction products comprising at least synthetic methane
Data Source
AI summary
The invention relates to a device (200) for the cogeneration of methanol and synthesis methane, comprising a CO2 hydrogenation device (100) for producing methanol from a syngas containing dihydrogen, H2 and carbon dioxide CO2, and a methanation reactor (205) for producing synthesis methane. The hydrogenation device comprises: a CO 2 hydrogenation reactor (105) for producing at least methanol CH 3OH; a condenser (145) for the hydrogenation reaction products leaving the reactor (105), intended to separate at least methanol and water form the excess syngas following the hydrogenation reaction; a first line (150) for the recirculation of the excess cold syngas leaving the condenser (145), connecting the outlet (155) of the condenser and the inlet (110) of the hydrogenation reactor (105), comprising a recirculator (160) for said syngas; a means (165) for measuring the flow rate of the methanol condensed by the condenser; and a means (170) for controlling the second recirculator, configured to control the recirculation of a quantity of excess hydrogen reaction products, determined according to the measured condensed methanol flow rate and a second given set value (175). The methanation reactor (205) comprises: an inlet (210) for part of the hydrogen products comprising at least the excess syngas following the hydrogenation reaction, and an outlet (215) for the methanation reaction products comprising at least the synthesis methane.