Decarboniser-Calciner Sorbent Loop for Fuel Gas Processing
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Solution Overview
Problem
Industrial plants face challenges in achieving flexible fuel usage and carbon capture with existing technologies, which incur significant energy penalties and costs, particularly in decarbonizing Syngas, Hydrogas, and Natural Gas/Synthetic Natural Gas (NG/SNG) to produce hydrogen and separate carbon dioxide streams efficiently.
Innovation Solution
A system and method utilizing a decarboniser and calciner segment with controlled CO2 partial pressures and temperatures, where a solid sorbent reacts with fuel gas and steam to produce a decarbonised fuel gas stream and a separate CO2 stream, with heat exchange between segments to minimize energy penalties, and incorporating a solid catalyst like iron oxide to activate reactions.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Object-generated harmful factors
If pre-combustion carbon capture technologies (Benfield separation process and Water Gas Shift reaction) are used to decarbonize Syngas, then carbon dioxide can be separated and sequestered, but significant energy penalty and capture costs are incurred
Solution Approach 1:
The patent combines the Water Gas Shift reaction and CO2 separation processes into an integrated system where the exothermic WGS reaction provides heat for the endothermic calcination process, merging two previously separate operations into a thermally coupled system that reduces external energy requirements
Solution Approach 2:
The patent converts the harmful CO2 that needs to be removed into a useful resource by using it as a carbonating agent for the sorbent regeneration process, and utilizes the exothermic heat from the WGS reaction to drive the endothermic calcination, turning waste heat into a beneficial energy source
2Object-generated harmful factors
If decarbonation processes are implemented to produce separate hydrogen and carbon dioxide streams, then carbon capture efficiency is improved, but operational flexibility and adaptability to different fuel inputs are reduced
Solution Approach 1:
The patent designs a universal decarbonization system that can process multiple fuel types (Syngas, Hydrogas, Natural Gas, Synthetic Natural Gas) through the same Water Gas Shift and sorbent-based separation mechanism, making the system adaptable to different fuel inputs while maintaining consistent CO2 separation performance
Solution Approach 2:
The patent employs dynamic control of operating parameters (temperature, pressure, steam-to-gas ratio) to optimize the decarbonization process for different fuel types and operational regimes, allowing the system to adapt its performance characteristics based on the specific fuel being processed
3Productivity
If high capital cost industrial processing plants are designed for specific fuel types, then processing efficiency is optimized, but operational flexibility to switch between different fuels is lost
Solution Approach 1:
The patent divides the processing system into distinct functional segments (gasification unit, Water Gas Shift unit, sorbent separation unit, calcination unit) that can operate independently and be optimized for different fuel types, allowing flexibility in fuel input while maintaining overall processing efficiency
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 efficient decarbonisation of various fuel gases with low energy penalties, allowing for flexible operation and reduced carbon emissions, while maintaining high capture efficiency and operational flexibility, suitable for integrated gasification combined cycle (IGCC) and natural gas combined cycle (NGCC) processes.
Implementation Method 1
The steam reacts with carbon monoxide in the fuel gas, or produced from the fuel gas in the decarboniser, to produce CO2 for adsorption by the solid sorbent
Implementation Method 2
a calciner segment configured such that the solid sorbent from the decarboniser segment reacts therein to release the carbon as CO2 into the CO2 gas stream
Implementation Method 3
CO2 partial pressures and temperatures in the decarboniser and calciner segments respectively are controlled such that the temperature in the decarboniser segment is higher than the temperature in the calciner such that heat is provided from the decarboniser to the calciner
Implementation Method 4
incorporating a solid catalyst like iron oxide to activate reactions
Data Source
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AI summary
A method and system for processing an input fuel gas and steam to produce separate CO2 and output fuel gas streams. The method comprises the steps of using a decarboniser segment for reacting at least a solid sorbent reacts with the fuel gas and steam to remove carbon from the input fuel gas and to produce the output fuel gas stream in an exhaust gas from the decarboniser; using a calciner segment for reacting the solid sorbent from the decarboniser segment therein to release the CO2 into the CO2 gas stream; wherein CO2 partial pressures and temperatures in the decarboniser and calciner segments respectively are controlled such that the temperature in the decarboniser segment is higher than the temperature in the calciner.