Catalytic Partial Oxidation In-Situ Coke Removal
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Solution Overview
Problem
Existing catalytic partial oxidation processes face challenges in efficiently removing coke deposits during operation, leading to reduced hydrogen yield and potential reactor clogging, with existing methods requiring process shutdowns and inefficient coke removal.
Innovation Solution
A process involving alternating fuel-rich and fuel-lean feed ratios in a catalytic partial oxidation reactor to maintain a constant hydrogen yield by varying the hydrocarbon fuel and oxidant feed ratios, allowing for in-situ coke removal without shutting down the process.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Object-generated harmful factors
If conventional coke removal methods are used, then coke deposits are removed, but the process must be shut down resulting in loss of hydrogen production
Solution Approach 1:
The patent applies periodic action by alternating between fuel-rich conditions (for hydrogen production) and fuel-lean conditions (for coke removal) in a cyclic manner. The process switches between these two operational modes periodically, allowing coke removal to occur during fuel-lean phases while maintaining hydrogen production during fuel-rich phases, thus eliminating the need for complete process shutdowns.
Solution Approach 2:
The patent implements continuity of useful action by ensuring that hydrogen production continues uninterrupted through the use of fuel-rich conditions during designated production phases. The coke removal operations are performed in a manner that does not completely stop the useful action of hydrogen generation, maintaining continuous operational benefit throughout the process cycle.
2Productivity
If fuel-rich conditions are maintained for hydrogen production, then hydrogen yield is maximized, but coke deposits accumulate on catalyst and reactor surfaces
Solution Approach 1:
The patent uses periodic action by systematically alternating between fuel-rich operational phases (that maximize hydrogen yield) and fuel-lean phases ( that remove coke deposits). This periodic switching prevents continuous coke accumulation while maintaining high hydrogen production during the fuel-rich phases, resolving the contradiction between productivity and harmful deposit formation.
Solution Approach 2:
The patent applies parameter changes by dynamically adjusting the fuel-to-oxidant ratio between fuel-rich and fuel-lean conditions. This parameter modification allows the system to transition between hydrogen production mode and coke removal mode, controlling the formation and removal of coke deposits while optimizing hydrogen yield during production phases.
3Reliability
If coke removal is performed frequently to prevent clogging, then reactor reliability is improved, but hydrogen production time is reduced
Solution Approach 1:
The patent implements periodic action by establishing regular cycles of fuel-rich and fuel-lean conditions. This systematic periodic operation ensures that coke removal occurs at predetermined intervals through fuel-lean phases, maintaining reactor reliability and preventing clogging while maximizing hydrogen production during fuel-rich phases, thus optimizing the balance between reliability and productivity.
Solution Approach 2:
The patent maintains continuity of useful action by ensuring that coke removal operations are integrated into the continuous operational cycle rather than requiring separate shutdown periods. The fuel-lean phases for coke removal are part of the continuous cyclic operation, allowing hydrogen production to resume immediately afterward without interruption, thus preserving maximum production time while maintaining reactor reliability.
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 effectively reduces coke deposits while maintaining a high and steady yield of hydrogen, extending the operable time of the reactor and catalyst without interrupting the hydrogen production process.
Implementation Method 1
contacting the hydrocarbon fuel and oxidant with a catalyst in the reactor for a fuel-rich cycle-time sufficient to produce at least one partially-oxidized reaction product
Implementation Method 2
maintaining the fuel-lean feed ratio for a fuel-lean cycle-time sufficient to reduce coke deposits
Implementation Method 3
a hydrogen-containing molecule, such as, a hydrocarbon, an alcohol, and/or water, is decomposed using a catalytic reforming reaction
Implementation Method 4
a hydrogen-containing molecule, such as, a hydrocarbon, an alcohol, and/or water, is decomposed using a catalytic reforming reaction, a pyrolysis reaction
Data Source
AI summary
A process of catalytic partial oxidation of a hydrocarbon fuel with an oxidant to produce partially-oxidized reaction products including hydrogen, with simultaneous in-situ coke removal. The process involves feeding a hydrocarbon fuel and an oxidant to a reactor in a fuel-rich feed ratio; reacting the fuel and oxidant for a fuel-rich cycle-time so as to produce a partially-oxidized reaction product; varying the fuel feed, or the oxidant feed, or both feeds to produce a fuel-lean feed to the reactor; maintaining the fuel-lean feed for a fuel-lean cycle-time sufficient to reduce coke deposits while maintaining a substantially constant yield of partially-oxidized reaction product; and alternating between the fuel-rich and fuel-lean operating cycles.