CO2 Separator for Gas-to-Liquids Plants
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Solution Overview
Problem
There is a long-standing need for systems and methods to effectively separate, capture, and utilize CO2 and H2 from process or waste gas streams, particularly from hydrocarbon-based fuel sources, to convert them into value-added products while reducing environmental impact and improving carbon efficiency.
Innovation Solution
The development of a gas-to-liquids plant with a primary synthesis loop at high pressure, incorporating a CO2 separator that uses mechanical or chemical/physical separation methods to capture CO2, which can be recycled and reused or sequestered, and a system that eliminates the need for hydrogen separation by adjusting syngas ratios, thereby reducing energy intensity and capital costs.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Loss of energy
If traditional CO2 separation methods are used in gas-to-liquids plants, then CO2 capture is achieved, but energy intensity and capital costs increase due to the need for hydrogen separation
Solution Approach 1:
The patent extracts CO2 separation from the traditional hydrogen separation step by implementing a dedicated CO2 separator unit that operates independently. This allows CO2 to be removed directly from the synthesis loop without requiring complete hydrogen separation, thereby reducing energy intensity while maintaining effective CO2 capture for utilization or storage
Solution Approach 2:
The CO2 separator is designed to perform multiple functions: it separates CO2 from the synthesis gas stream, adjusts the syngas ratio for optimal methanol synthesis, and provides a concentrated CO2 stream for downstream utilization. This multi-functionality eliminates the need for separate hydrogen separation equipment, reducing both capital costs and energy consumption
2Object-generated harmful factors
If CO2 is captured and separated from process streams, then carbon emissions are reduced, but capital costs and process complexity increase
Solution Approach 1:
The patent merges the CO2 separation function with the existing synthesis loop by positioning the CO2 separator at a strategic point where CO2 concentration is naturally higher. This integration allows CO2 capture to be achieved without adding completely separate capture infrastructure, thereby reducing capital costs and process complexity while effectively reducing carbon emissions through CO2 utilization or storage
3Device complexity
If hydrogen separation is eliminated by adjusting syngas ratios, then capital costs are reduced, but control precision requirements increase
Solution Approach 1:
The patent implements feedback control mechanisms that continuously monitor the syngas composition and automatically adjust process parameters to maintain optimal H2/CO ratios. This feedback system ensures that eliminating the hydrogen separation step does not compromise product quality, as the control system dynamically compensates for ratio variations, thereby reducing capital costs without sacrificing manufacturing precision
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 approach enables the efficient conversion of stranded gas resources into products like methanol, reduces carbon emissions, and generates revenue through CO2 utilization and tax credits, while minimizing capital and energy intensity in the carbon capture process.
Implementation Method 1
a CO2 separator that removes CO2 from a high-pressure process stream after condensation and collection of liquid or easily condensable products
Implementation Method 2
wherein the CO2 separator operates based on chemical/physical separation of CO2
Data Source
AI summary
There are provided CCUS systems and methods having gas-to-liquid systems and processes, e.g., for processing flare gas to methanol. In these systems an air-breathing engine reformer produces a syngas intermediate that is further converted to methanol in a downstream synthesis step. The CCUS system has a CO2 separator that receives a gas-phase stream and separates this stream into two streams, a CO2-rich stream and a CO2-depleted stream. The CCUS systems may further have a hydrogen separator that receive a gas-phase stream and separates that stream into a hydrogen-rich stream and a hydrogen-depleted stream. The CO2-rich stream can be used for use in EOR, storage or both.