Cobalt Mixed Oxide Catalyst Start-Up for Synthesis Gas
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Solution Overview
Problem
Current synthesis gas production methods using Co-based catalysts face challenges in achieving high conversion rates and selectivity while minimizing by-products, particularly during the start-up phase of the reforming process.
Innovation Solution
A continuous process for reforming hydrocarbons to synthesis gas, where a reactor with a mixed oxide catalyst comprising cobalt and oxygen is used, with a specific sequence of inert and reactant gas streams containing hydrocarbons, carbon dioxide, and water, allowing for continuous reforming conditions that optimize catalyst activity and reduce by-product formation.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If a common start-up phase is used (passing inert gas then reactant gas without CO2), then the catalyst is protected from initial deactivation, but the catalyst activity and conversion rates remain low during start-up
Solution Approach 1:
The patent applies preliminary action by introducing carbon dioxide into the reactant gas stream before the catalyst is fully activated, rather than waiting for a separate activation phase. This pre-introduction of CO2 prepares the catalyst for its intended operating conditions from the outset, avoiding the need for later adjustments and achieving high conversion rates immediately during the start-up phase.
Solution Approach 2:
The patent changes the compositional parameter of the reactant gas stream by including carbon dioxide from the beginning of the reactant gas introduction phase. This parameter change (adding CO2 to the gas composition) directly improves catalyst activity and conversion rates, resolving the contradiction between productivity and reliability during start-up.
2Productivity
If the reactant gas stream does not comprise carbon dioxide during initial phase, then catalyst deactivation is minimized, but conversion rates and catalyst activity are reduced
Solution Approach 1:
The patent merges the catalyst activation function with the main reforming reaction by introducing carbon dioxide into the reactant gas stream from the beginning. This consolidation eliminates the need for separate activation and reaction phases, simplifying the overall process while maintaining high conversion rates and catalyst activity throughout operation.
Solution Approach 2:
The patent ensures continuity of useful action by having the catalyst perform its intended reforming function continuously from the start of reactant gas introduction. The presence of carbon dioxide in the gas stream from the beginning allows the catalyst to maintain high activity and conversion rates without interruption or phase transitions, improving both productivity and process simplicity.
3Productivity
If steam reforming phase is used without carbon dioxide, then catalyst stability is maintained, but the size of reactor and catalyst quantity required increases
Solution Approach 1:
The patent changes the compositional parameter of the reactant gas stream by including carbon dioxide from the beginning, which enhances catalyst activity and conversion rates. This parameter change allows for more efficient hydrocarbon conversion, thereby reducing the required reactor volume and catalyst quantity while maintaining high productivity throughout the process.
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 process enhances catalyst activity and stability, leading to improved conversion rates of hydrocarbons to hydrogen and carbon monoxide, reducing reactor size and catalyst requirements, and maintaining high CO2 conversion without significant methane conversion decline.
Implementation Method 1
a continuous process for reforming one or more hydrocarbons to a synthesis gas comprising hydrogen and carbon monoxide, in the presence of a catalyst, preferably a catalyst comprising a mixed oxide which particularly comprises cobalt
Implementation Method 2
continuously passing an inert gas stream through the reaction zone according to (i), said inert gas stream comprising one or more inert gases; continuously passing a reactant gas stream into the reaction zone obtained from (ii)
Data Source
AI summary
A continuous process for reforming one or more hydrocarbons to a synthesis gas comprising hydrogen and carbon monoxide, the start-up phase of said process comprising (i) providing a reactor comprising a reaction zone which comprises a catalyst comprising a mixed oxide comprising cobalt and oxygen; (ii) continuously passing an inert gas stream through the reaction zone according to (i), said inert gas stream comprising one or more inert gases; (iii) continuously passing a reactant gas stream into the reaction zone obtained from (ii), wherein from 95 to 100 volume-% of the reactant gas stream passed into the reaction zone consist of the one or more hydrocarbons, carbon dioxide, and water; subjecting said reactant gas stream to reforming conditions in said reaction zone; and removing a product stream from said reaction zone, said product stream comprising hydrogen and carbon monoxide.