Cyclic Catalytic System for CO2 Conversion to Syngas
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Solution Overview
Problem
Current technologies for converting natural gas into synthesis gas emit significant CO2 and produce limited CO/H2 ratios, posing challenges for downstream chemical production and requiring more sustainable solutions that can integrate wide ranges of CO/H2 ratios.
Innovation Solution
A cyclic catalytic system with reactor zones operating in two modes, where methane is converted into hydrogen and solid carbon in one mode, and carbon dioxide reacts with the deposited carbon to produce carbon monoxide in another mode, allowing for the separation of hydrogen and carbon monoxide in the gas phase, with options for periodic feed switching or catalyst circulation.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If traditional SMR, POX, or ATR reforming technologies are used to convert natural gas into synthesis gas, then hydrogen production is achieved, but significant CO2 emissions occur (8 to 15 kg CO2/kg H2)
Solution Approach 1:
The patent converts CO2, traditionally a harmful emission, into a useful reactant for dry reforming of methane. By introducing CO2 into the reforming process, it serves dual purposes: acting as a reactant to produce synthesis gas (CO and H2) and consuming excess carbon that would otherwise form deposits, thereby converting a harmful substance into a beneficial resource
Solution Approach 2:
The patent fundamentally changes the chemical reaction parameters by replacing conventional steam-based reforming with CO2-based dry reforming. This parameter change alters the reaction stoichiometry and thermodynamics, producing synthesis gas with different CO/H2 ratios while simultaneously reducing the carbon footprint of the process
2Productivity
If SMR, POX, or ATR reforming processes are used, then hydrogen is produced, but the CO/H2 ratio is limited and not adaptable to various downstream chemical production processes
Solution Approach 1:
The patent introduces dynamic control capabilities by adjusting operational parameters such as CO2 to methane feed ratio, temperature, and pressure to dynamically tune the CO/H2 ratio in the synthesis gas output. This enables the system to adapt to different downstream process requirements rather than producing a fixed composition gas
Solution Approach 2:
The dry reforming process serves multiple functions simultaneously: it produces hydrogen, generates carbon monoxide, consumes CO2 emissions, and provides flexible CO/H2 ratio control. This multi-functionality makes the system versatile for various downstream applications including ammonia synthesis, methanol production, and liquid fuel synthesis
3Productivity
If methane decomposition using heterogeneous catalysts is used, then hydrogen is produced, but carbon formation on the catalyst occurs and stability is compromised
Solution Approach 1:
The patent converts the harmful carbon deposition that deactivates catalysts into a useful resource by introducing CO2. The CO2 reacts with the deposited carbon through the dry reforming reaction, gasifying the carbon deposits and regenerating active catalyst sites, thereby transforming a stability-destroying side reaction into a catalyst-regenerating beneficial process
Solution Approach 2:
The patent establishes a continuous cycle where carbon deposits formed during methane decomposition are continuously gasified by CO2, maintaining catalyst activity over extended periods. This continuous regeneration process eliminates the need for periodic catalyst replacement or regeneration, ensuring sustained productivity and 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 approach reduces CO2 footprint, generates carbon credits, and produces a wide range of CO/H2 ratios suitable for various downstream processes, integrating seamlessly with existing syngas facilities and reducing separation challenges compared to traditional SMR, ATR, and POX processes.
Implementation Method 1
converted over a solid catalyst into hydrogen and solid carbon, and the solid carbon is deposited on the solid catalyst
Implementation Method 2
carbon dioxide reacts with the deposited carbon to produce carbon monoxide
Data Source
AI summary
A process is provided that can convert the available CO2 stream (from any captured source) and CH4 (or natural gas, or hydrocarbon gas) stream to separated streams of CO and H2. Multiple options exist for utilization. Synthesis gas can be integrated with an existing syngas facility or combined with H2 from an electrolyze to make methanol or FT synthesis to make liquid fuels. When operating the process with separated H2 and CO streams. These can be integrated into different chemical processes and not necessarily mixed together. For example, H2 can be sold as a product, and CO can be used as a feedstock to make chemicals. The present disclosure is a desirable add-on to an industrial facility to process CO2 emission into the value stream.